Service Manual

T870 Compact Track Loader

S/N ASWT11001 & Above
S/N B3BZ11001 & Above

7248302enUS (02-18) (E) Printed in U.S.A. ©2018 Bobcat Company. All rights reserved.
T4-B
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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

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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4 of 1052 1-2 T870 Service Manual
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 CONTENTS

SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

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

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

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

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

ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

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

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

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

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

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6 of 1052 1-4 T870 Service Manual
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 FOREWORD

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

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Spark Arrester Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

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8 of 1052 1-6 T870 Service Manual
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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
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 all machine fluid

be legible and in the correct levels.
location.

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-0617 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
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-0617 SM

10 of 1052 1-8 T870 Service Manual

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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.
AVOID INJURY OR DEATH
Instructions are necessary before operating or • Machine signs (decals) instruct on the safe operation
servicing machine. Read and understand the and care of your Bobcat machine or attachment. The
Operation & Maintenance Manual, Operator’s signs and their locations are shown in the Operation
Handbook and signs (decals) on machine. Follow & Maintenance Manual. Replacement signs are
warnings and instructions in the manuals when available from your Bobcat dealer.
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or • An Operator’s Handbook fastened to the operator
service. Untrained operators and failure to follow cab. It’s brief instructions are convenient to the
instructions can cause injury or death. operator. The handbook is available from your dealer
W-2003-0807
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

gives general safety information.

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

• The Skid-Steer Loader Operator Training Course is

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

• The Skid-Steer Loader Safety Video is available from

WARNING your Bobcat dealer or at bobcat.com/training or
bobcat.com.

The signal word WARNING on the machine and in the

manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107

SI SSL-1016 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)
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-1016SM

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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.
cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Ultra Low Sulfur Diesel (ULSD) poses a greater static
ignition hazard than earlier diesel formulations with
All fuels, most lubricants and some coolants mixtures are higher Sulfur content. Avoid death or serious injury from
flammable. Flammable fluids that are leaking or spilled fire or explosion. Consult with your fuel or fuel system
onto hot surfaces or onto electrical components can supplier to ensure the delivery system is in compliance
cause a fire. with fueling standards for proper grounding and bonding
practices.
Operation
Starting
Do not use the machine where exhaust, arcs, sparks or
hot components can contact flammable material, Do not use ether or starting fluids on any engine that has
explosive dust or gases. glow plugs or air intake heater. These starting aids can
cause explosion and injure you or bystanders.
Electrical
Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump starting.

Spark Arrester Exhaust System

The spark arrester exhaust system is designed to control

the emission of hot particles from the engine and exhaust
Check all electrical wiring and connections for damage. system, but the muffler and the exhaust gases are still
Keep the battery terminals clean and tight. Repair or hot.
replace any damaged part or wires that are loose or
frayed. Check the spark arrester exhaust system regularly to
make sure it is maintained and working properly. Use the
Battery gas can explode and cause serious injury. Use procedure in the Operation & Maintenance Manual for
the procedure in the Operation & Maintenance Manual cleaning the spark arrester muffler (if equipped).
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-1016 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

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-1016 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

1
Figure 1

1 P121092A

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

on the side of the engine below the oil fill cap.

P-90642D

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 NA3095

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.

15 of 1052 1-13 T870 Service Manual

DELIVERY REPORT

Figure 4

NA3106

The delivery report [Figure 4] contains a list of items that

must be explained or shown to the owner or operator by
the dealer when the Bobcat loader is delivered.

The delivery report must be reviewed and signed by the

owner or operator and the dealer.

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LOADER IDENTIFICATION

2 20
1 11
3
19
4 12

5 18
13

10

14
6
9
7 8 15 17
16
NA1838
NA9416

ITEM DESCRIPTION ITEM DESCRIPTION

Operation & Maintenance Manual and Operator’s
1 11 Lift Cylinder (Both Sides)
Handbook
2 Front Lights 12 Rear Grille
3 Grab Handles 13 Back-up Alarm [C]
4 Operator Seat with Seat Belt and Seat Bar 14 Rear Work Lights and Taillights
5 Tilt Cylinders 15 Rear Door
Bucket [A] Rear Tie-down (Both Sides) Front Tie-down located
6 16
behind Bucket
7 Bucket Steps 17 Track
8 Step 18 Lift Arm Support Device
9 Alternate Front Tie-down (Both Sides) 19 Lift Arm
10 Front Auxiliary Quick Couplers 20 Operator Cab (ROPS and FOPS) [B]

[A] Bucket – Several different buckets and other attachments are available for the Bobcat loader.
[B] ROPS – Roll-Over Protective Structure per ISO 3471 and FOPS – Falling-Object Protective Structure per ISO 3449,
Level I. Level II is available.
[C] Optional or Field Accessory, (Not Standard Equipment.)

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18 of 1052 1-16 T870 Service Manual
 SAFETY AND MAINTENANCE

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

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

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-3

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
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 - 7217666 . . . . . . . . . . . . . . . . . . . . . . 10-61-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1
Remote Start Tool (Service Tool) - 7022042 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

ENGINE AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 And Adding Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-4
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-5

19 of 1052 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-4

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
Replacing Reservoir Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-6

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

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

PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Rear Window Removal (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Rear Window Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-2
External Access (Rear Window With Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-2
External Access (Rear Window With Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . 10-180-3
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-3

SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

20 of 1052 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
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-85424A

Read the Removal and Installation, Disassembly and 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 1052 10-10-1 T870 Service Manual

22 of 1052 10-10-2 T870 Service Manual
LIFT ARM SUPPORT DEVICE

Description

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

are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death.
W-2572-0407

Figure 10-20-1

P121445A

The lift arm support device (Item 1) [Figure 10-20-1] is

used to support the lift arms while working on a machine
with the lift arms up.

A decal (Item 2) [Figure 10-20-1] located on the right

side of the operator cab provides instructions for
installing and removing the lift arm support device.

The procedures are described in more detail on the

following pages. (See Installing on Page 10-20-2.) and
(See Removing on Page 10-20-3.)

23 of 1052 10-20-1 T870 Service Manual

LIFT ARM SUPPORT DEVICE (CONT’D) The operator must stay in the operator seat with the seat
belt fastened and the seat bar lowered until the lift arm
Installing support device is installed.

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

DANGER Figure 10-20-3

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 P-90677A
unless supported by an approved lift arm
support. Replace if damaged. Have a second person install the lift arm support device
D-1009-0409
over the rod of one of the lift cylinders [Figure 10-20-3].

Remove attachment from the loader. (See Operation And The lift arm support device must be tight against the
Maintenance Manual.) cylinder rod.

Figure 10-20-2 Figure 10-20-4

P-90640B

P-85463A P-90672A P-90640C

Put jackstands under the rear corners of the loader frame Lower the lift arms slowly until the lift arm support device
(Inset) [Figure 10-20-2]. is held between the lift arms and the lift cylinder. The tabs
of the lift arm support device must go past the end of the
Remove the lift arm support device (Item 1) [Figure 10- cylinder (Inset) [Figure 10-20-4].
20-2] from the storage position.

24 of 1052 10-20-2 T870 Service Manual

LIFT ARM SUPPORT DEVICE (CONT’D) Figure 10-20-6

Removing

DANGER

P121445A
P-90328

AVOID DEATH Return the lift arm support device to the storage position
• Disconnecting or loosening any hydraulic and secure with the clamping knobs [Figure 10-20-6].
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. Remove the jackstands.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409

The operator must be in the operator’s seat, with the seat

belt fastened and seat bar lowered, until the lift arm
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.

Figure 10-20-5

P-90677A

Have a second person remove the lift arm support device

[Figure 10-20-5].

Lower the lift arms all the way and stop the engine.

25 of 1052 10-20-3 T870 Service Manual

26 of 1052 10-20-4 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 cab, mounting and hardware for damage.
Never modify the cab. Replace the cab and hardware if Figure 10-30-1
damaged.

ROPS - Roll-Over Protective Structure per ISO 3471 and

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

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.

27 of 1052 10-30-1 T870 Service Manual

OPERATOR CAB (CONT’D) Support the operator cab and release the latching
mechanism (Inset) [Figure 10-30-4]. Remove your hand
Raising (Cont’d) from the latch mechanism when the operator cab is past
the latch stop. Use both hands to lower the operator cab
Figure 10-30-3 all the way down.

WARNING
PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
when the cab is past the latch stop.
W-2469-0803

Figure 10-30-5
P-90564F
Hardware Removed Hardware Installed

Lift on the grab handles and bottom of the operator cab

[Figure 10-30-3] slowly until the operator cab is all the
way up and the latching mechanism engages.

Lowering

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
P100236A 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.

Remove the jackstands.

P100953 P-90565B

Pull down on the bottom of the operator cab until stopped

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

NOTE: The weight of the operator cab increases

when equipped with options and accessories,
such as: cab door, heater, and air
conditioning. In these cases, the operator cab
may need to be raised slightly from the latch
to be able to release the latch.

28 of 1052 10-30-2 T870 Service Manual

OPERATOR CAB (CONT’D)

Cab Door Sensor

This machine may be equipped with a Cab Door Sensor.

Figure 10-30-6

P-68116B

The cab door has a sensor (Item 1) [Figure 10-30-6]

installed that deactivates the lift and tilt valves when the
door is open.

Figure 10-30-7

NA3275

The LIFT AND TILT VALVE light (Item 1) [Figure 10-30-

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

The LIFT AND TILT VALVE light (Item 1) [Figure 10-30-

7] is ON when the door is open, the key switch is turned
to RUN, the seat bar is lowered, and the PRESS TO
OPERATE LOADER button is pressed.

[DOOR] will appear in the data display (Item 2) [Figure

10-30-7] when the door is open, the key switch is turned
to RUN, the seat bar is lowered, and the PRESS TO
OPERATE LOADER button is pressed.

29 of 1052 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.

• Prerinse 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

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.

30 of 1052 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.
• Prerinse 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 10-30-10
NA1819

Must be used as part of the Forestry Applications Kit to

prevent flying debris and objects from entering the
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.

P100984

• Inspect both emergency exit levers (Item 1) [Figure

10-30-10], linkages, and hardware for loose or
damaged parts.
• Repair or replace if necessary.

31 of 1052 10-30-5 T870 Service Manual

32 of 1052 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 P-85615A P-85616B

break and cause personal injury.

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.)

NOTE: Always disengage the auto idle feature when

loading or unloading the loader on a trailer.

Figure 10-40-1

P-90670C

Alternate Rear Tie-Down Alternate Front Tie-Down

P107246A P-85599B
1

P-90728C Use the following procedure to fasten the Bobcat loader

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

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

6. Use chain binders to tighten the chains.

33 of 1052 10-40-1 T870 Service Manual

34 of 1052 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.)

35 of 1052 10-50-1 T870 Service Manual

36 of 1052 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 Kit 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 wheels are
able to turn.

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.

37 of 1052 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].
Remove the service tool harness (Item 1) from the cover
(Item 2) [Figure 10-60-3]. Connect the service tool harness to the ACD connector
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.

38 of 1052 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
(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: adjusting the
steering linkage.

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.

39 of 1052 10-60-3 T870 Service Manual

REMOTE START TOOL - 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

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.

40 of 1052 10-60-4 T870 Service Manual

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

Remote Start Procedure (Cont'd)

WARNING
2
3 1
UNAUTHORIZED AND UNEXPECTED ENGINE
START-UP 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.
• Place the key switch of the Remote Start Tool in P16118
the RUN position to disconnect the operator
panel from the start circuit.
• Remove the operator panel key (key switch), lock The traction lock switch (Item 1) [Figure 10-60-13] is
the keypad with a unique password (keyless) or used to turn traction lock ON or OFF. Push the switch to
otherwise disable the starter before working in the override position. The switch will illuminate to indicate
the engine area. traction lock OVERRIDE, in this position the wheels are
W-2457-1110 able to turn.

Figure 10-60-12 The maximum flow / variable flow switch (Item 2) [Figure
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

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

WARNING
P16116
AVOID INJURY OR DEATH
• 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

41 of 1052 10-60-5 T870 Service Manual

REMOTE START TOOL - 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
auxiliary pressure [Figure 10-60-14].

42 of 1052 10-60-6 T870 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT -
7217666

Description

The Remote Start Tool (Service Tool) Kit is a

replacement tool for MEL1563 Remote Start Tool and
MEL1400B BOSS® Diagnostic Tool.

The Remote Start Tool (Service Tool) Kit, P/N 7217666,

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.

43 of 1052 10-61-1 T870 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-2
7217666 (CONT’D)
2
Remote Start Tool (Service Tool) - 7022042

Tools that will be needed to complete the following steps

5 3
are:

Order from Bobcat Parts P/N: 7217666 - Remote Start 6 4

Tool (Service Tool) Kit

Kit Includes:
1
7022042 - 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.

The RUN button (Item 3) [Figure 10-61-2] is used to turn

the Remote Start Tool (Service Tool) on and activates the
loader electrical 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.

44 of 1052 10-61-2 T870 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-5
7217666 (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
P-76678 tie-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- When the remote start procedure is completed, replace
61-3] is used to connect the Remote Start Tool (Service the loader connector cap (Item 1) [Figure 10-61-4] or
Tool) (Item 2) [Figure 10-61-3] to the electrical system on reconnect the attachment control harness to the loader
the 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).

45 of 1052 10-61-3 T870 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
7217666 (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
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

46 of 1052 10-61-4 T870 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-9
7217666 (CONT’D)

Remote Start Procedure

WARNING
UNAUTHORIZED AND UNEXPECTED ENGINE 1
START-UP 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.
• Place the key switch of the Remote Start Tool in
P-90973
the RUN position to disconnect the operator
panel from the start circuit.
• Remove the operator panel key (key switch), lock Loaders without an attachment control harness, remove
the keypad with a unique password (keyless) or the loader harness cap (Item 1) [Figure 10-61-9] and
otherwise disable the starter before working in connect the Loader Service Tool Harness from the
the engine area. Remote Start Tool (Service Tool).
W-2457-1110
NOTE: When using a Remote Start Tool (Service tool)
The tool listed will be needed to do the following harness on loaders not equipped with an
procedure: attachment control device, the Remote Start
Tool (Service Tool) harness attachment
7217666: Remote Start Tool (Service Tool) Kit control device connector must be capped.
Figure 10-61-8 Figure 10-61-10

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 Loaders with an attachment control harness (7 pin or 14
raised position for service and the service technician pin), the attachment harness (Item 1) must be
needs to turn on the loader or start the engine. Example: disconnected from the loader harness (Item 2) [Figure
adjusting 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.

47 of 1052 10-61-5 T870 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-12
7217666 (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
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 electrical 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

48 of 1052 10-61-6 T870 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-14
7217666 (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
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.

49 of 1052 10-61-7 T870 Service Manual

50 of 1052 10-61-8 T870 Service Manual
SERVICE SCHEDULE

Maintenance Intervals WARNING

Maintenance work must be done at regular intervals.
Failure to do so will result in excessive wear and early AVOID INJURY OR DEATH
failures. Instructions are necessary before operating or
servicing machine. Read and understand the
The service schedule is a guide for correct maintenance Operation & Maintenance Manual, Operator’s
of the Bobcat loader. 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

Every 10 Hours (Before Starting The Loader)

• Engine Oil – Check level and add as needed.

• Engine Air Filters and Air System – Check display panel. Service only when required. Check for leaks and damaged
components.
• Engine Cooling System – Clean debris from hydraulic fluid cooler and radiator assembly, fuel cooler, air conditioning
condenser (if equipped), rear grille, and screens on the rear door and engine cover. Check coolant level COLD and
add premixed coolant as needed.
• Fuel Filter – Check the display panel. Remove the trapped water when required.
• Lift Arms, Lift Links, Cylinders, Bob-Tach, Pivot Pins, Wedges – Lubricate with multipurpose lithium based grease.
• Seat Belt, Seat Belt Retractors, Seat Bar, Control Interlocks – Check the condition of seat belt. Clean or replace
seat belt retractors as needed. Check the seat bar and control interlocks for correct operation. Clean dirt and debris
from moving parts.
• Bobcat Interlock Control Systems (BICS™) – Check for correct function. Lift and Tilt functions MUST NOT operate
with seat bar raised.
• Front Horn / Back-up Alarm – Check for proper function.
• 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.
• Safety Signs and Safety Treads – Check for damaged signs (decals) and safety treads. Replace any signs or safety
treads that are damaged or worn.
• Hydraulic Fluid – Check fluid level and add as needed.
• Heater and Air Conditioning Filters (if equipped) – Clean or replace filters as needed.

SS CTL LF EXLF T4-B-0617

51 of 1052 10-70-1 T870 Service Manual

SERVICE SCHEDULE (CONT’D)

Maintenance Intervals (Cont’d)

Every 50 Hours

• Hydraulic Hoses and Tubelines – Check for damage and leaks. Repair or replace as needed.
• Parking Brake, Foot Pedals, Hand Controls and Steering Levers, or Joysticks – Check for correct operation.
Repair or adjust as needed.
• Track Drive Sprocket Nuts or Bolts – Check for loose sprocket nuts or bolts and tighten to correct torque.
• Track Tension – Check tension and adjust as needed.
• Engine / Hydrostatic Drive Belt – Perform at first 50 hours, then as scheduled. Check for wear or damage. Adjust
or replace as needed.
• Engine Oil and Filter – Perform at first 50 hours, then as scheduled. Replace oil and filter.

Every 100 Hours

• Battery – Check cables, connections, and electrolyte level; add distilled water as needed.
• Engine Oil and Filter – Perform every 100 hours when operating under severe conditions. Replace oil and filter.

Every 250 Hours or Every 12 Months

• Engine / Hydrostatic Drive Belt – Check for wear or damage. Adjust or replace as needed.
• Drive Belts (Alternator, air conditioning, water pump) – Check condition. Replace as needed.
• Bobcat Interlock Control System (BICS™) – Check the function of the lift arm bypass control.

Every 500 Hours or Every 12 Months

• Fuel Filter – Replace filter element.

• Hydraulic Charge Filter, Hydraulic Reservoir Breather Cap – Replace the charge filter and the reservoir breather
cap.
• Hydrostatic Motor Carrier – Replace fluid.
• Engine Oil and Filter – Replace oil and filter.
• Heater Coil and Air Conditioning Evaporator (if equipped) - Clean the heater coil and air conditioning evaporator.
Clean the plenum drains.

Every 1000 Hours or Every 12 Months

• Hydraulic / Hydrostatic Filter – Replace the hydraulic / hydrostatic filter.

• Hydraulic Reservoir – Replace the fluid.
• Engine Valves – Adjust the engine valve clearance.

Every 1500 Hours or Every 24 Months

• Coolant – Replace the coolant.

Every 3000 Hours or Every 36 Months

• Diesel Exhaust Fluid (DEF) / AdBlue® Filter – Replace the diesel exhaust fluid (DEF) / AdBlue® filter.

SS CTL LF EXLF T4-B-0617

52 of 1052 10-70-2 T870 Service Manual

ENGINE AIR CLEANER Figure 10-80-3

Replacing Filter Elements

Figure 10-80-1

1
3

P121219
NA3271

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

Replace the air filter elements only when necessary. The and discard.
service indicator (Item 1) will FLASH. Press the
Information button (Item 3) until the display screen shows NOTE: Make sure the filter housing is free of dirt and
the service codes. Service code [M0117] (Air Filter debris. Verify that sealing surfaces are clean.
Plugged) will show in the display screen (Item 2) [Figure DO NOT use compressed air.
10-80-1] when air filter change is necessary.
Install new outer filter. Push in until the filter contacts the
Replace the inner filter every second time the outer filter base of the housing.
is replaced or as indicated.
Install the cover and secure the latches [Figure 10-80-2].
Outer Filter
NOTE: The rubber boot attached to the air cleaner
Stop the engine and remove the rear grille. (See cover is an important part of the engine
Removing on Page 50-60-1.) cooling system and must remain correctly
installed on the air cleaner cover.
Figure 10-80-2
Install the rear grille.

P121218A

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

[Figure 10-80-2].

53 of 1052 10-80-1 T870 Service Manual

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

Replacing Filter Elements (Cont’d)

Inner Filter

Replace the inner filter only under the following 1

conditions:

• Replace the inner filter element every second time the

outer filter is replaced.

• After the outer element has been replaced, start the 2

engine and run at full rpm. If service code [M0117]
(Air Filter Plugged) is still displayed in the data
display, replace the inner filter element.
P121218A

Stop the engine and 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
[Figure 10-80-3]. NOTE: The rubber boot attached to the air cleaner
cover is an important part of the engine
Figure 10-80-4 cooling system and must remain correctly
installed on the air cleaner cover.

Install the rear grille.

P121220

Remove the inner filter (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. Push in until the filter contacts the
base of the housing.

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

54 of 1052 10-80-2 T870 Service Manual

ENGINE COOLING SYSTEM Cleaning

Check the cooling system every day to prevent over- See the SERVICE SCHEDULE for the correct service
heating, loss of performance or engine damage. interval. (See SERVICE SCHEDULE on Page 10-70-1.)

Maintenance Platform Stop the engine.

Figure 10-90-1

WARNING
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

Figure 10-90-2
P107266
1
A maintenance platform (Item 1) [Figure 10-90-1] is
available to facilitate access when cleaning the engine
cooling system.

3
P121169B

Use low air pressure or low water pressure to clean the

top of the rear grille (Item 1) [Figure 10-90-2].

Use low air pressure or low water pressure to clean the

engine cover screen (Item 2) [Figure 10-90-2].

Use low air pressure or low water pressure to clean the

rear door fan screens (Item 3) [Figure 10-90-2].

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

1.)

55 of 1052 10-90-1 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Use low air pressure or low water pressure to clean the
top of the hydraulic fluid cooler and radiator assembly
Cleaning (Cont’d) (Item 3) [Figure 10-90-4].

Loaders With Air Conditioning Return the support bar to storage position and lower the
air conditioning condenser.
Figure 10-90-3
Figure 10-90-5

1
1

2 2

P121216B

P121162

Use low air pressure or low water pressure to clean the

top of the air conditioning condenser (Item 1) [Figure 10- Ensure the air conditioning condenser is installed into the
90-3]. two slotted brackets [Figure 10-90-5]. (Right side
shown.)
Unhook the two rubber straps (Item 2) [Figure 10-90-3].
Ensure the clips (Item 1) are properly installed over the
NOTE: The air conditioning condenser fits into two two slotted brackets (Item 2) [Figure 10-90-5]. (Right
slotted brackets mounted on the hydraulic side shown.)
fluid cooler and radiator assembly. Ensure the
air conditioning condenser remains Fasten the two rubber straps [Figure 10-90-3].
connected to the brackets when raising and
lowering. NOTE: The air conditioning condenser can be lifted
out of the two slotted brackets by removing
Figure 10-90-4 the clips. This allows greater access to clean
the hydraulic fluid cooler and radiator
assembly.

NOTE: Be careful when removing and installing the

1 air conditioning condenser so that the air
conditioning condenser does not fall on the
hydraulic fluid cooler and radiator assembly
2 and damage the fins.
3
Skip ahead to All Loaders. (See All Loaders on Page 10-
90-3.)

P121217C

Pivot the air conditioning condenser (Item 1) up and

rotate the support bar (Item 2) [Figure 10-90-4] into
position.

56 of 1052 10-90-2 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) All Loaders

Cleaning (Cont’d) Figure 10-90-7

Loaders Without Air Conditioning

Figure 10-90-6 2

1 3
1

P121216C

Use low air pressure or low water pressure to clean the

P121097A
top of the fuel cooler (Item 2) [Figure 10-90-7].

The area between the fuel cooler and the hydraulic fluid
Use low air pressure or low water pressure to clean the cooler and radiator assembly will require occasional
top of the hydraulic fluid cooler and radiator assembly cleaning. Remove the bolt (Item 3) and lift the fuel cooler
(Item 1) [Figure 10-90-6]. up while sliding out of the brackets (Item 1) [Figure 10-
90-7].

NOTE: Be careful when removing and installing the

fuel cooler so that the fuel cooler does not fall
on the hydraulic fluid cooler and radiator
assembly and damage the fins.

Install the fuel cooler into the brackets. Install and tighten
the bolt [Figure 10-90-7].

Check the cooling system for leaks.

Install the rear grille.

57 of 1052 10-90-3 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D)

Checking And Adding Coolant

IMPORTANT
Check the engine coolant level every day before starting
the engine for the work shift. AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Stop the engine and remove the rear grille. (See
Removing on Page 50-60-1.) Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
Figure 10-90-8 damage.

Too little antifreeze reduces the additives which

1 protect the internal engine components; reduces the
boiling point and freeze protection of the system.

Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
I-2124-0497
2

Add premixed coolant, 47% water and 53% propylene

glycol to the coolant tank until the coolant level reaches
the upper level marker on the tank [Figure 10-90-8].

P121221A Install the coolant fill cap [Figure 10-90-8].

NOTE: The coolant fill cap must be tightened until the

Coolant must be between the top and bottom level
cap clicks.
markers (Item 2) [Figure 10-90-8] when the engine is
cold.
Install the rear grille.
NOTE: The loader is factory filled with propylene
glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.

Use a refractometer to check the condition of propylene

glycol in your cooling system.

WARNING
AVOID INJURY
Stop the engine and allow to cool before adding
coolant or you can be burned.
W-2106-0907

Remove the coolant fill cap (Item 1) [Figure 10-90-8] to

add coolant.

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

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.

58 of 1052 10-90-4 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 10-90-10

Removing And Replacing Coolant

See the SERVICE SCHEDULE for the correct service

interval. (See SERVICE SCHEDULE on Page 10-70-1.)

Stop the engine. Open the rear door and remove the rear
grille. (See Removing on Page 50-60-1.)

1
WARNING
AVOID INJURY
Do not remove engine coolant cap when the engine P121163
is hot. You can be seriously burned.
W-2607-0804
Pinch off the coolant hose attached to the engine oil
cooler using a locking hose pinching plier (Item 1)
NOTE: This procedure requires the use of a spare 19 [Figure 10-90-10] or similar tool.
mm (0.75 in) coolant hose approximately 600
mm (24 in) long. Install the coolant fill cap (Item 1) [Figure 10-90-9].

Figure 10-90-9 Figure 10-90-11

1 3
2

P121221A P121164

Remove the coolant fill cap (Item 1) [Figure 10-90-9]. Remove the clamp (Item 2) and disconnect the hose
(Item 3) from the engine oil cooler fitting (Item 1) [Figure
10-90-11].

Quickly install the spare 19 mm (0.75 in) coolant hose

onto the engine oil cooler fitting.

Drain the coolant into a container.

59 of 1052 10-90-5 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) The correct mixture of coolant to provide a -37°C (-34°F)
freeze protection is 5 L propylene glycol mixed with 4,4 L
Removing And Replacing Coolant (Cont’d) of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
of water.
Figure 10-90-12

1
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.

Too much antifreeze reduces cooling system

2 efficiency and may cause serious premature engine
damage.

Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
P121221A
boiling point and freeze protection of the system.

Always add a premixed solution. Adding full strength

Remove the coolant fill cap (Item 1) [Figure 10-90-12] to concentrated coolant can cause serious premature
drain the coolant faster. engine damage.
I-2124-0497
Remove the spare 19 mm (0.75 in) coolant hose from the
engine oil cooler fitting when the coolant has drained.
Add premixed coolant, 47% water and 53% propylene
glycol to the coolant tank until the coolant level reaches
Figure 10-90-13
the lower level marker on the tank (Item 2) [Figure 10-90-
9].

Install the coolant fill cap [Figure 10-90-9].

NOTE: The coolant fill cap must be tightened until the

cap clicks.

Install the rear grille.

2 Operate the engine until coolant reaches normal

operating temperature. Stop the engine.
1
Check the coolant level when cool. Add coolant as
needed. (See Checking And Adding Coolant on Page 10-
P121165 90-4.)

Install the coolant hose (Item 2) onto the engine oil cooler
fitting and install the clamp (Item 1) [Figure 10-90-13].

Remove the tool used to pinch off the coolant hose.

Recycle or dispose of used coolant in an environmentally

safe manner.

Mix new coolant in a separate container. (See Capacities

on Page SPEC-10-5.)

60 of 1052 10-90-6 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:
NOTE: Contact your local fuel supplier to receive
recommendations for your region. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
U.S. Standard (ASTM D975)
• Biodiesel blend fuel is an excellent medium for
Use only clean, high quality diesel fuel, Grade Number microbial growth and contamination that can cause
2-D or Grade Number 1-D. corrosion and plugging of fuel system components.

Ultra low sulfur diesel fuel must be used in this machine. • Use of biodiesel blend fuel may result in premature
Ultra low sulfur is defined as 15 mg/kg (15 ppm) sulfur failure of fuel system components, such as: plugged
maximum. fuel filters and deteriorated fuel lines.

The following is one suggested blending guideline that • Shorter maintenance intervals may be required, such
should prevent fuel gelling during cold temperatures: as: cleaning the fuel system and replacing fuel filters
and fuel lines.
TEMPERATURE GRADE 2-D GRADE 1-D
• Using biodiesel blended fuels containing more than
Above -9°C (+15°F) 100% 0% five percent biodiesel can affect engine life and cause
Down to -21°C (-5°F) 50% 50% deterioration of hoses, tubelines, injectors, injector
Below -21°C (-5°F) 0% 100% pump, and seals.

Apply the following guidelines if biodiesel blend fuel is

NOTE: Biodiesel blend fuel may also be used in this
used:
machine. Biodiesel blend fuel must contain
no more than five percent biodiesel mixed
• Ensure the fuel tank is as full as possible at all times
with ultra low sulfur petroleum based diesel.
to prevent moisture from collecting in the fuel tank.
This biodiesel blend fuel is commonly
marketed as B5 blended diesel fuel. B5
• Ensure that the fuel tank cap is securely tightened.
blended diesel fuel must meet ASTM
specifications.
• Biodiesel blend fuel can damage painted surfaces,
remove all spilled fuel from painted surfaces
E.U. Standard (EN590)
immediately.
Use only clean, high quality diesel fuel that meets the
• Drain all water from the fuel filter daily before
EN590 specifications listed below:
operating the machine.
• Ultra low sulfur diesel fuel defined as 10 mg/kg (10
• Do not exceed engine oil change interval. Extended
ppm) sulfur maximum
oil change intervals can cause engine damage.
• Diesel fuel with cetane number of 51.0 and above.
• Before vehicle storage; drain the fuel tank, refill with
100% petroleum diesel fuel, add fuel stabilizer, and
NOTE: Biodiesel blend fuel may also be used in this
operate the engine for at least 30 minutes.
machine. Biodiesel blend fuel must contain
no more than seven percent biodiesel mixed
NOTE: Biodiesel blend fuel does not have long term
with ultra low sulfur petroleum based diesel.
stability and should not be stored for more
This biodiesel blend fuel is commonly
than 3 months.
marketed as B7 blended diesel fuel. B7
blended diesel fuel must meet EN590
specifications.

61 of 1052 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

Stop the engine and 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].

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

1 1].

NOTE: The fuel fill cap must be tightened until the

cap clicks.

Close the rear door.

P121465
WARNING
Remove the fuel fill cap (Item 1) [Figure 10-100-1].
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

62 of 1052 10-100-2 T870 Service Manual

FUEL SYSTEM (CONT’D) Replacing Element

Fuel Filter See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
Removing Water
Stop the engine and open the rear door.
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.) Figure 10-100-4

Stop the engine and open the rear door.

3
Figure 10-100-3
1

1 2
P121903

Disconnect the electrical connector (Item 2) [Figure 10-

P121337
100-4].

Loosen the fuel filter head (Item 3) from the fuel filter
Loosen the drain (Item 1) [Figure 10-100-3] at the element (Item 1) [Figure 10-100-4]. Do NOT remove the
bottom of the filter to remove trapped water from the filter. hoses from the fuel filter head.

Securely tighten the drain. Loosen the clamps (Item 4) [Figure 10-100-4].

Remove the fuel filter element (Item 1) from the fuel filter
head (Item 3) [Figure 10-100-4].
WARNING
NOTE: Do NOT fill the new fuel filter element with fuel
at this time.
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
Put clean oil on the two new fuel filter element O-rings,
sparks or lighted tobacco away from fuel and oil.
install the element, and tighten to 13,5 N•m (10 ft-lb)
Failure to use care around combustibles can cause
torque.
explosion or fire.
W-2103-0508
Install the fuel filter assembly into the clamps and tighten.
Connect the electrical connector [Figure 10-100-4].
Close the rear door.
Remove air from the fuel system. (See Removing Air
From The Fuel System on Page 10-100-4.)

63 of 1052 10-100-3 T870 Service Manual

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

Fuel Filter (Cont’d) After replacing the filter element or if the fuel tank has run
out of fuel, the air must be removed from the fuel system
Replacing Element (Cont’d) before starting the engine.

WARNING WARNING
AVOID INJURY OR DEATH AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames, Diesel fuel or hydraulic fluid under pressure can
sparks or lighted tobacco away from fuel and oil. penetrate skin or eyes, causing serious injury or
Failure to use care around combustibles can cause death. Fluid leaks under pressure may not be visible.
explosion or fire. Use a piece of cardboard or wood to find leaks. Do
W-2103-0508 not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
Close the rear door. from a physician familiar with this injury.
W-2072-0807
Start the engine and allow to operate for one minute.
Figure 10-100-5

WARNING
AVOID INJURY OR DEATH 1
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 2
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 P121904

Stop the engine and check for leaks at the filter. Open the air vent plug (Item 1) [Figure 10-100-5] on the
fuel filter assembly three full turns.

Squeeze the hand pump (priming bulb) (Item 2) [Figure

10-100-5] until fuel flows from the air vent plug with no air
bubbles.

Close the air vent plug (Item 1) [Figure 10-100-5].

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

64 of 1052 10-100-4 T870 Service Manual

ENGINE LUBRICATION SYSTEM Engine Oil Chart

Checking And Adding Engine Oil Figure 10-110-2

ENGINE CRANKCASE OIL
Check the engine oil level every day before starting the Recommended SAE Viscosity Number
engine for the work shift.

Figure 10-110-1

Refer to temperature range anticipated before next

oil change
Must use API Category CJ-4 or better, or ACEA E9 or
better
1
Do not use API Category FA-4 engine oil
2 [1] SAE 10W-30
[2] SAE 15W-40
P121156 [3] Bobcat Synthetic Oil – SAE 5W-40

Bobcat engine oils are recommended for use in this

Park the machine on level ground. Stop the engine. Open
machine. If Bobcat engine oil is not available, use a good
the rear door and remove the dipstick (Item 1) [Figure
quality engine oil that meets API Service Category of
10-110-1].
CJ-4 or better, or ACEA E9 or better [Figure 10-110-2].
Keep the oil level between the marks on the dipstick. Do
not overfill.

Remove the oil fill cap (Item 2) [Figure 10-110-1] to add

engine oil.
IMPORTANT
AVOID ENGINE DAMAGE
Use of API Service Category FA-4 engine oil is not
approved and may cause irreversible damage to the
WARNING engine.
I-2384-0916

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

Close the rear door.

65 of 1052 10-110-1 T870 Service Manual

ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-110-4

Removing And Replacing Oil And Filter

For the SERVICE SCHEDULE for the correct service

interval. (See SERVICE SCHEDULE on Page 10-70-1.)

Operate the engine until coolant reaches normal

operating temperature. Stop the engine.

Figure 10-110-3

P-90498A

P-90497B

Remove the oil drain cap (Item 1) [Figure 10-110-4] from

the oil drain hose and drain the oil into a container.
1 Recycle or dispose of used oil in an environmentally safe
manner.

2 Install and tighten the oil drain cap [Figure 10-110-4].

3 Install the cover and the cover mounting bolts [Figure 10-
P-90499A 110-3]. Tighten both bolts.

The oil drain hose is located behind a cover under the Open the rear door.
right rear corner of the loader (Inset) [Figure 10-110-3].

Remove two cover mounting bolts (Item 1) [Figure 10-

110-3].

Loosen the one cover mounting bolts (Item 2) and slide

the cover (Item 3) to the rear of the loader to remove.

66 of 1052 10-110-2 T870 Service Manual

ENGINE LUBRICATION SYSTEM (CONT’D)

Removing And Replacing Oil And Filter (Cont’d) WARNING

Figure 10-110-5
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

2
Stop the engine and check for leaks at the filter.
3
Remove the dipstick (Item 2) [Figure 10-110-5] and
check the oil level.
P121156
Add oil as needed if oil level is not at the top mark on the
dipstick. Install the dipstick and close the rear door.
Remove the oil filter (Item 3) [Figure 10-110-5] and clean
the filter base.

Put clean oil on the new filter gasket, install the new filter,
and hand tighten. Use genuine Bobcat filter only.
WARNING
Remove the oil fill cap (Item 1) [Figure 10-110-5]. AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
Put oil into the engine and replace the oil fill cap. (See sparks or lighted tobacco away from fuel and oil.
Capacities on Page SPEC-10-5.) Do not overfill. Failure to use care around combustibles can cause
explosion or fire.
Start the engine and allow to operate for several minutes. W-2103-0508

67 of 1052 10-110-3 T870 Service Manual

68 of 1052 10-110-4 T870 Service Manual
HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart

Checking And Adding Fluid Figure 10-120-3

HYDRAULIC / HYDROSTATIC FLUID
Check the hydraulic / hydrostatic fluid level every day RECOMMENDED ISO VISCOSITY GRADE (VG) AND
before starting the work shift. 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] BOBCAT All-Season Fluid
1 [2] BOBCAT Synthetic Fluid
[3] 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.)
[4] VG 100; Minimum VI 130
[5] VG 46; Minimum VI 150
P-90661A
Bobcat hydraulic fluids are recommended for use in this
Check the fluid level in the sight gauge (Item 1) [Figure machine. If Bobcat hydraulic fluid is not available, use a
10-120-1]. Keep the fluid level within the operating range. good quality hydraulic fluid meeting the viscosity grade
and viscosity index shown in the chart [Figure 10-120-3].
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,
sparks or lighted tobacco away from fuel and oil.
1 Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

P121074A

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.

69 of 1052 10-120-1 T870 Service Manual

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

Removing And Replacing Hydraulic Fluid

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

Replace the fluid if it becomes contaminated or after

major repair.

Always replace the hydraulic / hydrostatic filter and the

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.) P100033

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

1.) Remove the right side access cover bolts (Item 1)
[Figure 10-120-5] and remove the cover. (Lift arms
Figure 10-120-4 shown raised for visual clarity.)

Figure 10-120-6

1 1
2

P121074A

P115442
Remove the hydraulic fill cap (Item 1) [Figure 10-120-4].

The drain hose is located behind the fan motor.

Remove the clamp (Item 1). Pinch off the hose (Item 2)
[Figure 10-120-6] near the fitting and disconnect hose
from the fitting. Route the hose out the side of the loader
and drain the fluid into a container.

Connect the hose to the fitting when the fluid stops

draining. Install the clamp [Figure 10-120-6].

70 of 1052 10-120-2 T870 Service Manual

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)

Removing And Replacing Hydraulic Fluid (Cont’d) WARNING

Recycle or dispose of used fluid in an environmentally
safe manner. 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.
WARNING 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
AVOID INJURY OR DEATH from a physician familiar with this injury.
Always clean up spilled fuel or oil. Keep heat, flames, W-2072-0807
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
Stop the engine and check for leaks.
explosion or fire.
W-2103-0508
Check the fluid level in the reservoir and add as needed.
(See Checking And Adding Fluid on Page 10-120-1.)
Install the side access cover and bolts [Figure 10-120-5].

Figure 10-120-7

P121073A

Remove and clean the hydraulic fill screen (Item 1)

[Figure 10-120-7]. Use low air pressure to dry the
screen.

Install hydraulic fill screen and add the correct fluid to the
reservoir until the fluid level is within the operating range
of the sight gauge. (See Capacities on Page SPEC-10-
5.) and (See Checking And Adding Fluid on Page 10-
120-1.)

Install the hydraulic fill cap.

Install the rear grille.

Start the engine and operate the loader hydraulic

controls.

71 of 1052 10-120-3 T870 Service Manual

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Install new filter element ensuring that element is fully
seated in the housing.
Removing And Replacing Hydraulic / Hydrostatic
Filter Remove the filter cap O-rings (Item 3) [Figure 10-120-9]
and discard.
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.) Install new filter cap O-rings and lubricate with clean oil.

Stop the engine and remove the rear grille. (See NOTE: The filter cap O-rings are not the same size.
Removing on Page 50-60-1.) Take care to install each O-ring in the correct
location.
Clean the top of the filter housing.
Install the filter cap and bolts. Alternate tightening the
Figure 10-120-8 bolts to draw the cap down evenly. Tighten the bolts to 27
– 41N•m (20 – 30 ft-lb) torque.

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

P121214 Install the rear grille.

Start the engine and operate the loader hydraulic

Remove the bolts (Item 1) and rotate the filter cap (Item controls.
2) [Figure 10-120-8] slightly.

Slowly pry the filter cap off the housing by hand.

Figure 10-120-9
WARNING
1 AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
2 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

Stop the engine and check for leaks at the filter.

3
Check the fluid level in the reservoir and add as needed.
P121072A P121580A (See Checking And Adding Fluid on Page 10-120-1.)

Remove the filter element (Item 2) [Figure 10-120-9] and

discard.

Lubricate the O-ring (Item 1) [Figure 10-120-9] on new

filter element with clean oil.

72 of 1052 10-120-4 T870 Service Manual

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)

Removing And Replacing Hydraulic Charge Filter WARNING

See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.) AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
Stop the engine and raise the operator cab. (See Raising sparks or lighted tobacco away from fuel and oil.
on Page 10-30-1.) Failure to use care around combustibles can cause
explosion or fire.
Figure 10-120-10 W-2103-0508

Install the right side access cover and bolts [Figure 10-
1
120-10].

Start the engine and operate the loader hydraulic

controls.

WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
P100033 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
Remove the right side access cover bolts (Item 1)
not use your bare hand. Wear safety goggles. If fluid
[Figure 10-120-10] and remove the access cover. (Lift
enters skin or eyes, get immediate medical attention
arms shown raised for visual clarity.)
from a doctor familiar with this injury.
W-2072-EN-0909
Figure 10-120-11

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.)

P121104

Put a suitable container below the filter, remove the filter

(Item 1) [Figure 10-120-11], and clean the filter base.

Put clean oil on the new filter gasket, install the new filter,
and tighten the filter to 37 – 45 N•m (27 – 33 ft-lb) torque.

Recycle or dispose of used fluid in an environmentally

safe manner.

73 of 1052 10-120-5 T870 Service Manual

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)

Replacing Reservoir Breather Cap

See the SERVICE SCHEDULE for the correct

replacement interval. (See SERVICE SCHEDULE on
Page 10-70-1.)

Stop the engine and remove the rear grille. (See

Removing on Page 50-60-1.)

Figure 10-120-12

P121074A

Remove the breather cap (Item 1) [Figure 10-120-12]

and discard.

Install new breather cap.

Install the rear grille.

74 of 1052 10-120-6 T870 Service Manual

BOB-TACH (HAND LEVER) Figure 10-130-2

Inspection And Maintenance

1
Figure 10-130-1

Both wedges must

contact lower edge of
holes in the attachment
mounting frame.

P-31233A NA3098

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

P-85513A through the holes in the attachment mounting frame.

The spring loaded wedges (Item 1) must contact the

Move the Bob-Tach levers down to engage the wedges lower edge of the holes in the attachment mounting
[Figure 10-130-1]. frame (Item 2) [Figure 10-130-2].

The levers and wedges must move freely. If the wedge does not contact the lower edge of the holes
[Figure 10-130-2], the attachment will be loose and can
come off the Bob-Tach.
WARNING Figure 10-130-3

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

NA13065S

Inspect the mounting frame on the attachment and Bob-

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

Look for cracked welds.

Lubricate the wedges. (See ENGINE AIR CLEANER on

Page 10-80-1.) and (See PIVOT PINS on Page 10-150-
1.)

75 of 1052 10-130-1 T870 Service Manual

76 of 1052 10-130-2 T870 Service Manual
BOB-TACH (POWER) Figure 10-131-2

This machine may be equipped with a Power Bob-Tach®.

1
Inspection And Maintenance

Figure 10-131-1 2

1 Both wedges must

contact lower edge of
holes in the attachment
mounting frame.

P-31233A NA3098

2 The wedges (Item 1) [Figure 10-131-2] must extend

through the holes in the attachment mounting frame.

NA3234A The spring loaded wedges (Item 1) must contact the

lower edge of the holes in the attachment mounting
frame (Item 2) [Figure 10-131-2].
Push and hold the BOB-TACH WEDGES “UP” switch
(Item 1) until wedges are fully raised. Push and hold the If the wedges do not contact the lower edge of the holes
BOB-TACH WEDGES “DOWN” switch (Item 2) [Figure [Figure 10-131-2], the attachment will be loose and can
10-131-1] until the wedges are fully down. come off the Bob-Tach.

The levers and wedges must move freely. Figure 10-131-3

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

NA13065S

Inspect the mounting frame on the attachment and Bob-

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

Look for cracked welds.

Lubricate the wedges. (See SERVICE SCHEDULE on

Page 10-70-1.) and (See LUBRICATING THE LOADER
on Page 10-140-1.)

77 of 1052 10-131-1 T870 Service Manual

78 of 1052 10-131-2 T870 Service Manual
LUBRICATING THE LOADER Lubricate the following:

Lubrication Locations Figure 10-140-2

See the SERCVICE SCHEDULE for the correct service
interval. (See ENGINE AIR CLEANER on Page 10-80-1.)

Record the operating hours each time you lubricate the

Bobcat loader.
1
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.

Stop the engine.

Figure 10-140-1 P100713A

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

2
4 Figure 10-140-3
8

9 10
11 2
5
3
6

7
P107399E

The grease fitting locations [Figure 10-140-1] are

described in more detail in the following figures.
P-90542A

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

79 of 1052 10-140-1 T870 Service Manual

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

Lubrication Locations (Cont’d)

Figure 10-140-4

3
P-90570A

5. Rear Control Link (Both Sides) (2) [Figure 10-140-6].

P-90572A
Figure 10-140-7

3. Base End Lift Cylinder (Both Sides) (2) [Figure 10-

140-4].

Figure 10-140-5

6
4

P-90544A

6. Front Control Link (Both Sides) (2) [Figure 10-140-7].

P100730

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

140-5].

80 of 1052 10-140-2 T870 Service Manual

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

Lubrication Locations (Cont’d)

Figure 10-140-8

7
P107960

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

P-31308A
140-10].

Figure 10-140-11
7. Bob-Tach Wedge (Both Sides) (2) [Figure 10-140-8].

Figure 10-140-9

10
8

P107961

P109929A
10. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-140-
11].

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

140-9].

81 of 1052 10-140-3 T870 Service Manual

LUBRICATING THE LOADER (CONT’D)

Lubrication Locations (Cont’d)

Figure 10-140-12

11

P107959

11. Power Bob-Tach Hydraulic Cylinder (2) [Figure 10-

140-12]. (If equipped with Power Bob-Tach.)

82 of 1052 10-140-4 T870 Service Manual

PIVOT PINS

Inspection And Maintenance

Figure 10-150-1

P107293A

All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and locknut (Item 1) [Figure
10-150-1].

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

40 ft-lb) torque.

83 of 1052 10-150-1 T870 Service Manual

84 of 1052 10-150-2 T870 Service Manual
LOADER STORAGE AND RETURN TO SERVICE Return To Service

Storage After the Bobcat loader has been in storage, perform the
procedures below to return the loader to service:
You may decide to store your Bobcat loader for an
extended period of time. Perform the procedures below • Check the engine oil and hydraulic fluid levels; check
for storage: coolant level.

• Thoroughly clean the loader including the engine • Install a fully charged battery.
compartment.
• Remove grease from exposed cylinder rods.
• Lubricate the loader.
• Check all belt tensions.
• Replace worn or damaged parts.
• Be sure all shields and guards are in position.
• Park the loader in a dry protected shelter.
• Lubricate the loader.
• Lower the lift arms all the way and put the bucket flat
on the ground. • Check track condition and remove blocks from under
frame.
• Put blocks under the frame to remove weight from the
tracks. • Remove cover from exhaust pipe opening.

• Put grease on any exposed cylinder rods. • Start the engine and operate for a few minutes while
observing the instrument panels and systems for
• Put fuel stabilizer in the fuel tank and operate the correct operation.
engine a few minutes to circulate the stabilizer to the
pump and fuel injectors. • Operate machine, check for correct function.

If biodiesel blend fuel has been used, perform the • Stop the engine and check for leaks. Repair as
following: needed.

Drain the fuel tank, refill with 100% petroleum diesel

fuel, add fuel stabilizer, and operate 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 the battery in a
cool dry location above freezing temperatures and
charge the battery periodically during storage.

• Cover the exhaust pipe opening.

• Tag the machine to indicate that the machine is in

storage condition.

85 of 1052 10-160-1 T870 Service Manual

86 of 1052 10-160-2 T870 Service Manual
STOPPING THE ENGINE AND LEAVING THE LOADER Unbuckle the seat belt.

Procedure (Standard Key Panel) Remove the key from the switch
to prevent operation of the loader by unauthorized
Stop the loader on level ground. personnel.

Fully lower the lift arms and put the attachment flat on the NOTE: Activating the Password Lockout Feature on
ground. machines with the Keyless Start Panel or the
Deluxe Instrumentation Panel allows
Figure 10-170-1 operation of the loader without using a
password. (See Password Lockout Feature on
Page 60-190-2.) or (See Password Lockout
Feature on Page 60-191-1.)

Figure 10-170-3

P107184

P-85737A P-85735A
Set the engine speed control to the low idle position
[Figure 10-170-1].
Exit the loader using grab handles, safety tread, and
Engage the parking brake. steps (maintaining a three-point contact) [Figure 10-170-
3].
Figure 10-170-2

1 1
WARNING
AVOID INJURY OR DEATH
Before you leave the operator’s seat:
• Lower the lift arms and put the attachment flat on
the ground.
• Stop the engine.
• Engage the parking brake.
P-90688A P-90214C
• Raise the seat bar.
• Move all controls to the NEUTRAL / LOCKED
position to make sure the lift, tilt and traction
Turn the key switch to the STOP position (Item 1) [Figure drive functions are deactivated.
10-170-2].
The seat bar system must deactivate these functions
NOTE: If the loader lights are ON, they will remain ON when the seat bar is up. See your Bobcat dealer for
for approximately 90 seconds after turning service if controls do not deactivate.
the loader OFF. W-2463-1110

NOTE: The cooling fans in the rear door may

continue to operate for several minutes.

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

87 of 1052 10-170-1 T870 Service Manual

88 of 1052 10-170-2 T870 Service Manual
EMERGENCY EXIT Rear Window Removal (Latches)

The front opening on the operator cab and rear window Figure 10-180-2
provide exits.

Rear Window Identification 1

Figure 10-180-1

Latches Rubber Cord

2
P-85309A
1
P-85309B P-64994D
Turn both latches (Item 1) [Figure 10-180-2] in until they
disengage from the window frame.
There are two different procedures for removing the rear
window from your machine: Push the rear window out of the rear of the operator cab.

1. This window is equipped with latches [Figure 10-180- Figure 10-180-3

1].

2. This window is equipped with a rubber cord and tag

[Figure 10-180-1].

NOTE: Use these procedures to remove the rear

window only under emergency conditions.
Damage to machine may occur.

P-90676

Exit through the rear of the operator cab [Figure 10-180-

3].

89 of 1052 10-180-1 T870 Service Manual

EMERGENCY EXIT (CONT’D) External Access (Rear Window With Latches)

Rear Window Removal (Rubber Cord) Figure 10-180-6

Figure 10-180-4
1

P-64994C

P-90669A

Pull on the tag on the top of the rear window to remove

the rubber cord [Figure 10-180-4]. The rear window can be removed from outside the loader
using a T40 TORX® Drive tool. Turn both screws (Item 1)
Push the rear window out of the rear of the operator cab. [Figure 10-180-6] counterclockwise until the latches
disengage from the window frame. Pull the top of the
Figure 10-180-5 window away from the cab and lift up to remove.

OR

Figure 10-180-7

P-90676

Exit through the rear of the operator cab [Figure 10-180-

5].

P-90669C

A kit is available to allow removal of the latch equipped

rear window from outside the machine without tools.

Turn both knobs (Item 1) [Figure 10-180-7]

counterclockwise until the latches disengage from the
window frame. Pull the top of the window away from the
cab and lift up to remove.

90 of 1052 10-180-2 T870 Service Manual

EMERGENCY EXIT (CONT’D) Front Door

External Access (Rear Window With Rubber Cord) This machine may be equipped with a front door.

A kit is available to allow removal of the rubber cord NOTE: Use this procedure to remove the front door
equipped rear window from outside the machine. only under emergency conditions. Damage to
machine may occur.
Figure 10-180-8
Figure 10-180-9

P13982
P-90725

Pull both handles (Item 1) [Figure 10-180-8] up and out

to remove the rear window. Turn both latches (Item 1) [Figure 10-180-9] down until
they disengage from the door frame.

Push the door out of the operator cab door frame and exit
through the opening.

91 of 1052 10-180-3 T870 Service Manual

EMERGENCY EXIT (CONT’D) Figure 10-180-12

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 10-180-10
1
1

P-90685

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

hinges (Item 2) [Figure 10-180-12] on the door. (Bottom
hinge shown)
2
Figure 10-180-13

P-85781A 1

Disconnect electrical connector (Item 2) and washer fluid

hose (Item 1) [Figure 10-180-10]. 2

Figure 10-180-11

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 10-180-13]
up to lock cast washer into place. (Bottom hinge shown)

Install door on loader. Install the gas spring socket on the

P-85588A P-85589A ball stud fitting. Install the clip into the hole in the gas
spring socket. Rotate the clip to lock into place [Figure
10-180-11].
Rotate and pull the clip (Item 1) out of the gas spring
socket. Pull the gas spring socket (Item 3) straight off the Connect electrical connector (Item 2) and washer fluid
ball stud fitting (Item 2) [Figure 10-180-11]. hose (Item 1) [Figure 10-180-10].

Remove the door hinges from the loader.

92 of 1052 10-180-4 T870 Service Manual

SEAT BELT Figure 10-190-1

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

Check the seat belt daily for correct function. 2 4

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,
retractor (if equipped), hardware or any other obvious
problem should be replaced immediately. 5

The items below are referenced in [Figure 10-190-1].

NA3113

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.

5. Check the hardware on both sides of the seat.

Hardware should be tight. Hardware must not be
missing, rusted, corroded, or damaged.

93 of 1052 10-190-1 T870 Service Manual

94 of 1052 10-190-2 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

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-6

MAIN RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4
Auxiliary Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-5
Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-6

95 of 1052 20-01 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-2
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-18
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-18
Lift Spool Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-20
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-21
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-23
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-24
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-25
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-26
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28
Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29

96 of 1052 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-6
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-7
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-8
Load Check Valve Removal And Installation (Tilt And Auxiliary) . . . . . . . . . . . . . . . 20-41-9
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-41-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-41-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-41-11
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-41-11
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-12
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-14
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-16
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-27
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-27
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-31
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-31
Auxiliary Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-32
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-32

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-9
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-10
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-11

97 of 1052 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
Hydraulic Fluid Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-5

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
Testing Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-4
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-6

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-2

98 of 1052 20-04 T870 Service Manual

AUTOMATIC RIDE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-2
Checking The Pressure In The Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-5
Adding Nitrogen To The Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-7

99 of 1052 20-05 T870 Service Manual

100 of 1052 20-06 T870 Service Manual
 Printable Version Click Here

(PRINTED JUNE 2015)

V-1607legend
LEGEND
1 RESERVOIR: 19 PULL BUTTON ACTIVATED 36 VARIABLE CAPACITY DISPLACEMENT
Capacity at sight gauge . . 9,75 L (10.3 qt) DIRECTIONAL CONTROL VALVE - LIFT BIDIRECTIONAL HYDROSTATIC PUMP
System Capacity . . . . . . . 36 L (9.5 U.S. gal) ARM BY-PASS
37 CHECK VALVE – COLD WEATHER BY-PASS
2 SIGHT GAUGE 20 LIFT CYLINDER SPOOL - MADE TO With 345 kPa (3,45 bar) (50 psi) Spring
3 RESTRICT FLOW DURING BOOM 38
DIFFERENTIAL PRESSURE SWITCH: SERVO PISTON – Swash Plate
DOWN BUT NOT DURING BOOM UP
103 kPa (1,03 bar) (15 psi)
Normally Closed 21 ANTICAVITATION VALVE 39 RELIEF/REPLENISHING VALVE - HIGH
4 FILTER - HYDRAULIC (CANISTER) PRESSURE: 39645 kPa (396 bar) (5750 psi)
22 PROPORTIONAL RELIEF VALVE –
5 SPRING LOADED FILTER BY-PASS (Fan Speed Regulator): 10797 – 12300 kPa 40 RELIEF VALVE - CHARGE INLET:
VALVE: 1,72 kPa (1,7 bar) (25 psi) (108 - 123 bar) (1566 - 1784 psi) 3241 – 3585 kPa (32,4 – 35,8 bar) (470 – 520 psi)
6 DIAGNOSTIC COUPLER at High Engine Idle With 60 degrees C. (140 degrees F.) Fluid
23 SPRING LOADED FILTER BY-PASS VALVE:
7 RELIEF VALVE - MAIN: 517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi) 41 SOLENOID ACTIVATED DIRECTIONAL
27234 – 27924 kPa (272 - 279 bar) 24 FIXED CAPACITY DISPLACEMENT CONTROL VALVE – FORWARD/REVERSE
(3950 - 4050 psi) at Diagnostic Coupler 6 HYDRAULIC MOTOR
42 FILTER (Screen)
7A RELIEF VALVE - AUXILIARY: 25 FILTER - HYDRAULIC (CANISTER)
23787 – 24476 kPa (238 - 245 bar) 43 Not Used For This Model
26 SENSOR – CHARGE PRESSURE –
(3450 - 3550 psi) at Front Quick Couplers
8 Fan Filter
RELIEF/ANTICAVITATION VALVE -
27 FRONT AUXILIARY MANUAL PRESSURE 44 Not Used For This Model
PORT: 31026 kPa (310 bar) (4500 psi)
BLEED-OFF VALVE
9 RELIEF/ANTICAVITATION VALVE -
28 SENSOR – HYD. TEMPERATURE 45 Not Used For This Model
PORT 27579 kPa (276 bar) ( 4000 psi)
(AUXILIARY RELIEF IS OPTIONAL) 29 RESTRICTION - 1,7 mm (0.067 in) 46 SOLENOID ACTIVATED DIRECECTIONAL
10 SOLENOID ACTIVATED DIRECTIONAL CHECK VALVE - With 1379 kPa (13,8 bar) CONTROL VALVE – BRAKE
30
CONTROL VALVE - AUXILIARY (200 psi) Spring 47 FILTER - BRAKE
11 LOAD CHECK VALVE 31 DRIVE MOTOR SHUTTLE VALVE
12 ANTICAVITATION VALVE 48 HYDRAULIC PUMP . . . . . . . Gear Type
32 Not Used For This Model 87,1 L/min (23.0 U.S. gpm) at High Engine Idle
13 PILOTED ACTIVATED DIRECTIONAL 33 Not Used For This Model 49 CHARGE PUMP -
CONTROL VALVE - TILT CONTROL
14 51,1 L/min (13.5 U.S. gpm) at High Engine Idle
PILOTED ACTIVATED DIRECTIONAL
CONTROL VALVE - LIFT CONTROL
15 34 FIXED CAPACITY DISPLACEMENT
SOLENOID ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDROSTATIC
CONTROL VALVE - BICS CONTROL
MOTOR
16 FILTER - BICS CONTROL VALVE
(SCREEN) 35 HYDRAULIC BRAKE – SPRING APPLIED –
PRESSURE RELEASE (SAPR)
17 CHECK VALVE - With 100 kPa (1,0 bar) NOTE: Unless otherwise specified
(14.5 psi) Spring springs have NO significant
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) pressure value.

Printed in U.S.A. V-1607legend (5-14-15)

101 of 1052
 27
Male

INTEGRATED
COUPLER BLOCK
DRIVE MOTOR
Male

30 27
L

29
31 Female

HYDRAULIC CONTROL VALVE

9
34

10 10
A B
35
7A Auxiliary Spool
6

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

X 42 41
8 13

38
X Tilt Spool

39
39 12

SAPR BRAKE VALVE 11

M
M 42 LIFT CYLINDERS
47 A 8 14
B
47
M
3 40
Lift Spool
2 G 16
A B
45 M
1 46 M 42 20

11
39 15
39
X 7 18
6
16 2
38
17
X
42 41
1

19
T
OIL COOLER
36
R

48 37
RESERVOIR
2 (VENTED)

FILTER
1
VARIABLE SPEED HYDRAULIC
FAN MOTOR W/ INTEGRATED FILTER CANISTER
49
26 3

25 23

5
4 WORKING

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

34 DRAIN/RETURN MANIFOLD
Printable Version Click Here
HYDRAULIC/HYDROSTATIC SCHEMATIC
28 WITH NO OPTIONS
T870 (S/N ASWT11001 AND ABOVE)
31
(S/N B3BZ11001 AND ABOVE)
29
30
(PRINTED JUNE 2015)
L
102 of 1052 DRIVE MOTOR
7194198 (D)
Printed In U.S.A.
 Printable Version Click Here

- ASWT12124
- AB3BZ11253
(PRINTED FEBRUARY 2018)
V-1608legend
LEGEND
1 RESERVOIR: 20 LIFT CYLINDER SPOOL - MADE TO 39 RELIEF/REPLENISHING VALVE - HIGH 58 CHECK VALVE
Capacity at sight gauge . . 9,75 L (10.3 qt) RESTRICT FLOW DURING BOOM PRESSURE: 39645 kPa (396 bar) (5750 psi)
System Capacity . . . . . . . 36 L (9.5 U.S. gal) DOWN BUT NOT DURING BOOM UP 59 RESTRICTION - 0,25 mm (0.10 in)
40 RELIEF VALVE - CHARGE INLET:
2 SIGHT GAUGE 21 ANTICAVITATION VALVE 3241 – 3585 kPa (32,4 – 35,8 bar) (470 – 520
60 NOT USED FOR THIS MODEL
psi) at High Engine Idle With 60 degrees C.
3 DIFFERENTIAL PRESSURE SWITCH: 22 PROPORTIONAL RELIEF VALVE – (140 degrees F.) Fluid
103 kPa (1,03 bar) (15 psi) Normally Closed (Fan Speed Regulator): 10797 – 12300 kPa 61 NOT USED FOR THIS MODEL
41 SOLENOID ACTIVATED DIRECTIONAL
4 FILTER - HYDRAULIC (CANISTER) (108 - 123 bar) (1566 - 1784 psi)
CONTROL VALVE – FORWARD/REVERSE 62 FILTER – BOB-TACH VALVE
5 SPRING LOADED FILTER BY-PASS 23 SPRING LOADED FILTER BY-PASS VALVE:
VALVE: 1,72 kPa (1,7 bar) (25 psi) 42 FILTER (Screen) 63 PILOT ACTIVATED DIRECTIONAL
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
CONTROL VALVE - REAR AUXILIARY
6 DIAGNOSTIC COUPLER 24 FIXED CAPACITY DISPLACEMENT SOLENOID ACTIVATED DIRECECTIONAL
43 64 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
7 RELIEF VALVE - MAIN: HYDRAULIC MOTOR CONTROL VALVE – MAKE-UP
27234 – 27924 kPa (272 - 279 bar) 25 FILTER - HYDRAULIC (CANISTER) 65 SOLENOID ACTIVATED DIRECTIONAL
44 SOLENOID ACTIVATED DIRECECTIONAL
(3950 - 4050 psi) at Diagnostic Coupler 6 CONTROL VALVE - TWO COIL
26 SENSOR – CHARGE PRESSURE – CONTROL VALVE – 2 SPEED
7A RELIEF VALVE - AUXILIARY: 66 RESTRICTOR - 0,8 mm (0.031 in)
23787 – 24476 kPa (238 - 245 bar) Fan Filter 45 CHECK VALVE
(3450 - 3550 psi) at Front Quick Couplers 27 FRONT AUXILIARY MANUAL PRESSURE 67 LOAD SHUTTLE VALVE - BLEED OFF
46 SOLENOID ACTIVATED DIRECECTIONAL
BLEED-OFF VALVE
8 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE – BRAKE 68 SOLENOID ACTIVATED DIRECTIONAL
PORT 31026 kPa (310 bar) (4500 psi) 28 SENSOR – HYD. TEMPERATURE CONTROL VALVE - BASE
RELIEF/ANTICAVITATION VALVE - 47 FILTER - BRAKE
9 29 RESTRICTION: 1,7 mm (0.067 in) 69 SOLENOID ACTIVATED DIRECTIONAL
PORT 27579 kPa (276 bar) ( 4000 psi) CONTROL VALVE - ROD
48 HYDRAULIC PUMP . . . . . . . Gear Type
(AUXILIARY RELIEF IS OPTIONAL) 30 CHECK VALVE - With 1379 kPa (13,8 bar)
(200 psi) Spring 90,1 L/min (23.8 U.S. gpm) at High Engine Idle 70 SOLENOID ACTIVATED DIRECTIONAL
10 SOLENOID ACTIVATED DIRECTIONAL
31 DRIVE MOTOR SHUTTLE VALVE 49 CONTROL VALVE - BUCKET POSITION
CONTROL VALVE - AUXILIARY CHARGE PUMP -
VALVE (ON/OFF)
11 LOAD CHECK VALVE 32 HIGH PRESSURE SHUTTLE With 52,6 L/min (13.9 U.S. gpm) at High Engine Idle
71
INNER MAKE-UP SPOOL FLOW DIVIDER ADJUSTMENT VALVE
12 ANTICAVITATION VALVE 33 FIXED CAPACITY DISPLACEMENT 50 HIGH FLOW HYDRAULIC PUMP Gear Type 72 PILOTED ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDROSTATIC 51,5 L/min (13.6 U.S. gpm) at High Engine Idle CONTROL VALVE - FLOW CONTROL
13 PILOTED ACTIVATED DIRECTIONAL MOTOR – 2 SPEED 51 RELIEF VALVE – 17237 kPa (241 bar) SPOOL
CONTROL VALVE - TILT CONTROL
(3500 psi) 73 CHECK VALVE - BUCKET POSITION
14 PILOTED ACTIVATED DIRECTIONAL 34 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC 52 DUMP VALVE – ON / OFF VALVE
CONTROL VALVE - LIFT CONTROL
MOTOR 74 PILOTED ACTIVATED DIRECTIONAL
15 SOLENOID ACTIVATED DIRECTIONAL 53 PILOT ACTIVATED DIRECTIONAL CONTROL
35 HYDRAULIC BRAKE – SPRING APPLIED – CONTROL VALVE - UNLOADING
CONTROL VALVE - BICS CONTROL VALVE – HYDRAULIC POWERED BOB-TACH
SPOOL
16 FILTER - BICS CONTROL VALVE (SCREEN) PRESSURE RELEASE (SAPR) With Build-up Valve 275 kPa (2,75 bar) (40 psi)
54 FILTER - BOB-TACH VALVE 75 RIDE CONTROL VALVE
36 VARIABLE CAPACITY DISPLACEMENT
17 CHECK VALVE - With 100 kPa (1,0 bar)
(14.5 psi) Spring BIDIRECTIONAL HYDROSTATIC PUMP 55 RESTRICTION - 1,17 mm (0.46 in) 76 HIGH PRESSURE CHAMBER
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 37 CHECK VALVE – COLD WEATHER BY-PASS
56 SOLENOID ACTIVATED DIRECTIONAL 77 LOW PRESSURE CHAMBER
With 345 kPa (3,45 bar) (50 psi) Spring
19 PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL) NOTE: Unless otherwise specified
CONTROL VALVE – LIFT ARM BY-PASS 38 SERVO PISTON – Swash Plate 57 RELIEF VALVE - 24131 kPa (241 bar) (3500 psi) springs have NO significant
Printed in U.S.A. pressure value. V-1608legend (2-5-18)
103 of 1052
 27
Male

INTEGRATED
COUPLER BLOCK

Male
2-SPEED DRIVE MOTOR 27
30 45
L RIDE CONTROL
Female (OPTION)
31 29

OUT
HYDRAULIC CONTROL VALVE

LIFT CYLINDERS

9 76 77
X

75

33 9
32
REAR AUXILIARY VALVE
34 10
(OPTION) 10
FEMALE MALE
REAR QUICK
COUPLERS 7A Auxiliary Spool
6A
Z

A
35 B 67
BUCKET POSITIONING
VALVE (OPTIONAL)
69
68 E1 E2 A1 A2

HYDROSTATIC PUMP 9 11
E3
65 BOBCAT INTERLOCK CONTROL SYSTEM 70
R (BICS)
36 71
T B

66 8 13 72
X 42 41

38 Tilt Spool
73

X 64 D2

12
39 63
2-SPEED & 39 11
SAPR BRAKE
VALVE 74
P - in P - out 8 14
B A M 42 T C2
M
T A B C1 D1
47 M

40 Lift Spool
16
POWER BOBTACH CYLINDER
G (OPTIONAL)
P A B POWER BOBTACH
M VALVE (OPTIONAL) 20
B1 A1
47 M 42 11
58 57
44 15
46
TILT CYLINDERS
39
39 7 18
6
56 16
X 2
59
17
38
X 1
42 41 D
19
55
T 54
36 OIL COOLER RESERVOIR
R
48 (VENTED)
37 53 2

1
3
VARIABLE SPEED HYDRAULIC 5
FAN MOTOR W/ INTEGRATED FILTER
49
26 4
52
25 23 FILTER
CANISTER
50
51
FILTER WORKING
RESTRICTION
PRESSURE
CHARGE
35
B A PRESSURE
DRAIN /
Z
21 RETURN
24
22
33 34 P DR

32 DRAIN/RETURN MANIFOLD

Printable Version Click Here

28
X HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH ALL OPTIONS
T870 (S/N ASWT11001 - ASWT12124)
29
31 (S/N B3BZ11001 - B3BZ11253)
30 (PRINTED FEBRUARY 2018)
L
2-SPEED DRIVE MOTOR
104 of 1052 7194198 (D)

Printed In U.S.A.
 Printable Version Click Here

HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH ALL OPTIONS
T870 (S/N ASWT12125 AND ABOVE)
(S/N B3BZ11254 AND ABOVE)
(PRINTED FEBRUARY 2018)
V-1608legend
LEGEND
1 RESERVOIR: 20 LIFT CYLINDER SPOOL - MADE TO 39 RELIEF/REPLENISHING VALVE - HIGH 58 CHECK VALVE
Capacity at sight gauge . . 9,75 L (10.3 qt) RESTRICT FLOW DURING BOOM PRESSURE: 39645 kPa (396 bar) (5750 psi)
System Capacity . . . . . . . 36 L (9.5 U.S. gal) DOWN BUT NOT DURING BOOM UP 59 RESTRICTION - 0,25 mm (0.10 in)
40 RELIEF VALVE - CHARGE INLET:
2 SIGHT GAUGE 21 ANTICAVITATION VALVE 3241 – 3585 kPa (32,4 – 35,8 bar) (470 – 520 SOLENOID ACTIVATED DIRECTIONAL
60
psi) at High Engine Idle With 60 degrees C. CONTROL VALVE – Fan Reversing (Optional)
3 DIFFERENTIAL PRESSURE SWITCH: 22 PROPORTIONAL RELIEF VALVE – (140 degrees F.) Fluid
103 kPa (1,03 bar) (15 psi) Normally Closed (Fan Speed Regulator): 10797 – 12300 kPa 61 NOT USED FOR THIS MODEL
41 SOLENOID ACTIVATED DIRECTIONAL
4 FILTER - HYDRAULIC (CANISTER) (108 - 123 bar) (1566 - 1784 psi)
CONTROL VALVE – FORWARD/REVERSE 62 FILTER – BOB-TACH VALVE
5 SPRING LOADED FILTER BY-PASS 23 SPRING LOADED FILTER BY-PASS VALVE:
VALVE: 1,72 kPa (1,7 bar) (25 psi) 42 FILTER (Screen) 63 PILOT ACTIVATED DIRECTIONAL
517 – 572 kPa (5,2 - 5,7 bar) (75 - 83 psi)
CONTROL VALVE - REAR AUXILIARY
6 DIAGNOSTIC COUPLER 24 FIXED CAPACITY DISPLACEMENT 43 NOT USED FOR THIS MODEL 64 RELIEF VALVE: 22753 kPa (228 bar) (3300 psi)
7 RELIEF VALVE - MAIN: HYDRAULIC MOTOR
27234 – 27924 kPa (272 - 279 bar) 25 FILTER - HYDRAULIC (CANISTER) 65 SOLENOID ACTIVATED DIRECTIONAL
44 SOLENOID ACTIVATED DIRECECTIONAL
(3950 - 4050 psi) at Diagnostic Coupler 6 CONTROL VALVE - TWO COIL
26 SENSOR – CHARGE PRESSURE – CONTROL VALVE – 2 SPEED
7A RELIEF VALVE - AUXILIARY: 66 RESTRICTOR - 0,8 mm (0.031 in)
23787 – 24476 kPa (238 - 245 bar) Fan Filter 45 CHECK VALVE
(3450 - 3550 psi) at Front Quick Couplers 27 FRONT AUXILIARY MANUAL PRESSURE 67 LOAD SHUTTLE VALVE - BLEED OFF
46 SOLENOID ACTIVATED DIRECECTIONAL
BLEED-OFF VALVE
8 RELIEF/ANTICAVITATION VALVE - CONTROL VALVE – BRAKE 68 SOLENOID ACTIVATED DIRECTIONAL
PORT 31026 kPa (310 bar) (4500 psi) 28 SENSOR – HYD. TEMPERATURE CONTROL VALVE - BASE
RELIEF/ANTICAVITATION VALVE - 47 FILTER - BRAKE
9 29 RESTRICTION: 1,7 mm (0.067 in) 69 SOLENOID ACTIVATED DIRECTIONAL
PORT 27579 kPa (276 bar) ( 4000 psi) CONTROL VALVE - ROD
48 HYDRAULIC PUMP . . . . . . . Gear Type
(AUXILIARY RELIEF IS OPTIONAL) 30 CHECK VALVE - With 1379 kPa (13,8 bar)
(200 psi) Spring 90,1 L/min (23.8 U.S. gpm) at High Engine Idle 70 SOLENOID ACTIVATED DIRECTIONAL
10 SOLENOID ACTIVATED DIRECTIONAL
31 DRIVE MOTOR SHUTTLE VALVE 49 CONTROL VALVE - BUCKET POSITION
CONTROL VALVE - AUXILIARY CHARGE PUMP -
VALVE (ON/OFF)
11 LOAD CHECK VALVE 32 HIGH PRESSURE SHUTTLE With 52,6 L/min (13.9 U.S. gpm) at High Engine Idle
71
INNER MAKE-UP SPOOL FLOW DIVIDER ADJUSTMENT VALVE
12 ANTICAVITATION VALVE 33 FIXED CAPACITY DISPLACEMENT 50 HIGH FLOW HYDRAULIC PUMP Gear Type 72 PILOTED ACTIVATED DIRECTIONAL
BIDIRECTIONAL HYDROSTATIC 51,5 L/min (13.6 U.S. gpm) at High Engine Idle CONTROL VALVE - FLOW CONTROL
13 PILOTED ACTIVATED DIRECTIONAL MOTOR – 2 SPEED 51 RELIEF VALVE – 17237 kPa (241 bar) SPOOL
CONTROL VALVE - TILT CONTROL
(3500 psi) 73 CHECK VALVE - BUCKET POSITION
14 PILOTED ACTIVATED DIRECTIONAL 34 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC 52 DUMP VALVE – ON / OFF VALVE
CONTROL VALVE - LIFT CONTROL
MOTOR 74 PILOTED ACTIVATED DIRECTIONAL
15 SOLENOID ACTIVATED DIRECTIONAL 53 PILOT ACTIVATED DIRECTIONAL CONTROL
35 HYDRAULIC BRAKE – SPRING APPLIED – CONTROL VALVE - UNLOADING
CONTROL VALVE - BICS CONTROL VALVE – HYDRAULIC POWERED BOB-TACH
SPOOL
16 FILTER - BICS CONTROL VALVE (SCREEN) PRESSURE RELEASE (SAPR) With Build-up Valve 275 kPa (2,75 bar) (40 psi)
54 75 SOLENOID ACTIVATED DIRECTIONAL
36 VARIABLE CAPACITY DISPLACEMENT FILTER - BOB-TACH VALVE
17 CHECK VALVE - With 100 kPa (1,0 bar) CONTROL VALVE – Ride Control (OPTIONAL)
(14.5 psi) Spring BIDIRECTIONAL HYDROSTATIC PUMP 55 RESTRICTION - 1,17 mm (0.46 in) 76 ORIFICE WITH CHECK VALVE: 2,54 mm (0.10 in)
18 RESTRICTION . . . . . . . 2,0 mm (0.079 in) 37 CHECK VALVE – COLD WEATHER BY-PASS 77 ACCUMULATOR – Ride Control (OPTIONAL)
With 345 kPa (3,45 bar) (50 psi) Spring 56 SOLENOID ACTIVATED DIRECTIONAL
19 PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE (TWO COIL) 78 ORIFICE: 1,60 mm (0.063 in)
CONTROL VALVE – LIFT ARM BY-PASS 38 SERVO PISTON – Swash Plate 57 RELIEF VALVE - 24131 kPa (241 bar) (3500 psi) NOTE: Unless otherwise specified springs have NO
significant pressure value.
Printed in U.S.A. V-1608legend (2-5-18)
105 of 1052
 27
Male

INTEGRATED
COUPLER BLOCK

Male
2-SPEED DRIVE MOTOR 27
30 45
L
Female
31 29
RIDE CONTROL (OPTION)
76
OUT
HYDRAULIC CONTROL VALVE T2 ACC

T 77 LIFT CYLINDERS

78
9
X
P

75
33 9
CR2 CR
32 CB CB2

REAR AUXILIARY VALVE

34 10
(OPTION) 10
FEMALE MALE
REAR QUICK
COUPLERS 7A Auxiliary Spool
6A
Z

A
35 B 67
BUCKET POSITIONING
VALVE (OPTIONAL)
69
68 E1 E2 A1 A2
E3
HYDROSTATIC PUMP 9 11
65 BOBCAT INTERLOCK CONTROL SYSTEM 70
R (BICS)
36 71
T
B
66 8 13 72
X 42 41

38 Tilt Spool
73

X
64 D2

12
39 63
2-SPEED & 39 11
SAPR BRAKE
VALVE 74
P - in P - out T 8 14
B A M 42 C2
M
A B C1 D1
47 M
T
40 Lift Spool
16
POWER BOBTACH CYLINDER
G (OPTIONAL)
P A B POWER BOBTACH
M VALVE (OPTIONAL) 20
B1 A1
47 M 42 11
58 57
44 15
46
TILT CYLINDERS
39
39 7 18
6
X
56 16 2
59
17
38
X 1
42 41 D
19
55
T 54
36 OIL COOLER RESERVOIR
R
48 (VENTED)
37 53 2
1
3
VARIABLE SPEED HYD 5
FAN MOTOR W/ FILTER
49 26
& W/REVERSE OPTION
4
25
52
23
FILTER
CANISTER
50
51
1 4 21 FILTER WORKING
RESTRICTION

3
CHARGE
B
35 2
PRESSURE
A
24 DRAIN /
RETURN
Z 60
DR 22 P

33 34

32 DRAIN/RETURN MANIFOLD

Printable Version Click Here

X
28 HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH ALL OPTIONS
T870 (S/N ASWT12125 AND ABOVE)
31 (S/N B3BZ11254 AND ABOVE)
29

30 (PRINTED FEBRUARY 2018)

L
2-SPEED DRIVE MOTOR
7194198 H)
106 of 1052
Printed In U.S.A.
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.
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.

107 of 1052 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
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).

108 of 1052 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 the
allows free flow in one direction only. 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 Anti-cavitation 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-
RETURN VALVE- It is possible to MANUALLY ACTIVATED DIRECTION
open the valve by pilot pressure. CONTROL VALVE (Variable Position)
T
OUT IN
Joystick Controlled, variable pressure
P
to shift the pilot activated directional
control valve spool.
SHUTTLE VALVE - The Inlet port
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

FRONT

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.

109 of 1052 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 / ANTI-CAVITATION 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 -

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).

110 of 1052 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 ENGINE CONTROL UNIT (ECU) 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 4
position
The lift arms come down with the pedal in NEUTRAL position 4, 9, 10, 11
Lift Arm Bypass Control valve stuck 12
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-50-1.)
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.

111 of 1052 20-10-5 T870 Service Manual

112 of 1052 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.

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.

113 of 1052 20-20-1 T870 Service Manual

CYLINDER (LIFT) (CONT’D) Figure 20-20-4

Removal And Installation

NOTE: Remove only one cylinder at a time.

2
IMPORTANT 1

2
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.
P100298
I-2003-0888

Figure 20-20-3 Cap and plug both fittings on the cylinder (Item 1)
[Figure 20-20-4].

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.

1 Recycle or dispose of used fluid in an environmentally

safe manner.

P100296
WARNING
AVOID INJURY OR DEATH
Mark and disconnect the two hydraulic hoses (Item 1) Diesel fuel or hydraulic fluid under pressure can
[Figure 20-20-3]. 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
WARNING enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
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

114 of 1052 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.

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.

115 of 1052 20-20-3 T870 Service Manual

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

Removal And Installation (Cont’d)

DANGER
1

P109395
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.
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.

116 of 1052 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

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.

117 of 1052 20-20-5 T870 Service Manual

CYLINDER (LIFT) (CONT’D)

Parts Identification

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

1
5
7
10

9 8
10
6
11

12
13
6
17

14

15

16

NA12113S

118 of 1052 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

MEL1075 - Adjustable Gland Nut 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. 1

Figure 20-20-13
P121297

1
Remove the seal (Item 1) [Figure 20-20-15] from the
piston.

NOTE: If the fiber surface (Item 2) [Figure 20-20-15]

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

NOTE: The seal is a two piece seal.

Figure 20-20-16

P-48033
1

Use an Adjustable Gland Nut Wrench to loosen the head 2

(Item 1) [Figure 20-20-13] from the cylinder case.

Figure 20-20-14

3
4 2

P121296

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

20-16] from the cylinder head.

NOTE: The seal was replaced with an O-ring and

back-up O-ring. Use the version currently
P121294 supplied through parts.

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

119 of 1052 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.

Figure 20-20-18

P-48042

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

cylinder head.

120 of 1052 20-20-8 T870 Service Manual

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

Assembly

Use the following tools to assemble the cylinder:

MEL1396-1 - Universal Seal Expander

MEL1033 - Rod Seal Installation Tool
MEL1396-2 - Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench

Wash the cylinder parts in solvent and air dry them.

1
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
P121297
Always install new O-rings and seals during assembly.

Lubricate all O-rings and seals with hydraulic oil during Install the seal (Item 1) [Figure 20-20-20] on the piston.
installation.
Figure 20-20-21
Figure 20-20-19

N-22358
P7424

Use a ring compressor to compress the seal to the

Install the new seal on the tool and slowly stretch it until it correct size. Leave the piston in the compressor for
fits the piston [Figure 20-20-19]. approximately three minutes [Figure 20-20-21].

Allow the seal to stretch for 30 seconds before installing it

on the piston.

121 of 1052 20-20-9 T870 Service Manual

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

Assembly (Cont'd)

Figure 20-20-22

P7425

Install the rod seal in the head [Figure 20-20-24].

P121296
Figure 20-20-25

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

20-22] on the cylinder head.
2
NOTE: The seal was replaced with an O-ring and
back-up O-ring. Use the version currently
supplied through parts. 1

Figure 20-20-23

1
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 20-20-
25].

P-48043 P7427

Install the rod seal on the rod seal tool (MEL1033)

[Figure 20-20-23].

NOTE: During installation the spring side of the seal

(Item 1) [Figure 20-20-23] must be installed
toward the inside of the cylinder.

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

20-23].

122 of 1052 20-20-10 T870 Service Manual

CYLINDER (LIFT) (CONT’D)

Assembly (Cont'd)

Figure 20-20-26

2
1 3

P121294

NOTE: Clean and dry the threads before installing the

nut. Install the new nut from the kit.

Install the head (Item 1), spacer (Item 2) piston (Item 3),
and nut (Item 4) [Figure 20-20-26].

Tighten the nut (Item 4) [Figure 20-20-26] to 1491 N•m

(1100 ft-lb) torque.

Figure 20-20-27

P-48035

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

Using an Adjustable Gland Nut Wrench, tighten the head

(Item 1) [Figure 20-20-27] to 373 N•m (275 ft-lb) torque.

123 of 1052 20-20-11 T870 Service Manual

124 of 1052 20-20-12 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

P109407 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.
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.

125 of 1052 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.

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

Remove the attachment from the Bob-Tach. Roll the Bob- [Figure 20-21-5].
Tach forward
Cap the hoses and plug the fittings on the cylinder.
Stop the engine. Raise the seat bar.
Figure 20-21-6
Remove the retainer bolt and nut (Item 1) [Figure 20-21-
3] from the rod end pivot pin.

Installation: Tighten the retainer nut to 48 - 54 N•m (35 -

40 ft-lb) torque.
1
Figure 20-21-4

P-85648

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].

126 of 1052 20-21-2 T870 Service Manual

CYLINDER (TILT) (CONT’D)

Removal And Installation (Cont'd)

Figure 20-21-7

P109410

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

127 of 1052 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

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].

128 of 1052 20-21-4 T870 Service Manual

CYLINDER (TILT) (CONT’D)

Parts Identification

1. Tubeline
2. Case
3. Plug
4. O-ring
5. Grease Fitting
6. Clamp
7. Nut
8. Seal
9. Piston 5
10. Collar 6
11. Head
12. Wiper
13. Rod
14. Bushing 4 2
15. Back-up O-ring 3

7
8
1 9
4
3 10

8
4
11

4 12

15

13
5
14

NA14143S

129 of 1052 20-21-5 T870 Service Manual

CYLINDER (TILT) (CONT’D) Figure 20-21-13

Disassembly
2
4
Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook

MEL1075 - Adjustable Gland Nut Wrench

Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder. 1
3
Put the base end of the cylinder in a vise.

Figure 20-21-11
P109554

Remove the nut (Item 1), piston (Item 2), collar (Item 3)
and head (Item 4) [Figure 20-21-13].
1
Figure 20-21-14

P-85651B

Remove the bushing (Item 1) [Figure 20-21-11] with a

driver tool and hammer.

Figure 20-21-12
P109555

1 Remove the seal (Item 1) [Figure 20-21-14] from the

piston.

P106021

Use an Adjustable Gland Nut Wrench to loosen the head

(Item 1) [Figure 20-21-12] from the cylinder case.

130 of 1052 20-21-6 T870 Service Manual

CYLINDER (TILT) (CONT’D) Figure 20-21-17

Disassembly (Cont'd)

Figure 20-21-15

1
1

P-48042

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

P109556 cylinder head.

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

20-21-15] from the cylinder head.

NOTE: The seal was replaced with an O-ring and

back-up O-ring. Use the version currently
supplied through parts.

Figure 20-21-16

P-48040

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

the cylinder head.

131 of 1052 20-21-7 T870 Service Manual

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

Assembly

Use the following tools to assemble the cylinder:

1
MEL1396-1 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool
MEL1396-2 - Piston Ring Compressor
MEL1075 - Adjustable Gland Nut 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.
P109555
Always install new O-rings and seals during assembly.

Lubricate all O-rings and seals with hydraulic oil during Install the seal (Item 1) [Figure 20-21-19] on the cylinder
installation. piston.

Figure 20-21-18 Figure 20-21-20

P7424 N-22358

Install the new seal on the tool and slowly stretch it until it Use a ring compressor to compress the seal to the
fits the piston [Figure 20-21-18]. correct size. Leave the piston in the compressor for
approximately three minutes [Figure 20-21-20].
Allow the seal to stretch for 30 seconds before installing it
on the piston.

132 of 1052 20-21-8 T870 Service Manual

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

Assembly (Cont'd)

Figure 20-21-21 2

P-48041 P-48042

Install the wiper seal, with the wiper side of the seal (Item
P-48043 P7427 1) toward the outside of the head (Item 2) [Figure 20-21-
23].

Install the rod seal on the rod seal tool [Figure 20-21-21]. Figure 20-21-24

NOTE: During installation the spring side of the seal

(Item 1) [Figure 20-21-21] must be installed 1
2
toward the inside of the cylinder.

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

21-21].

Figure 20-21-22

P109556

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

21-24] on the cylinder head.

NOTE: The seal was replaced with an O-ring and

back-up O-ring. Use the version currently
supplied through parts.
P7425

Install the rod seal in the head [Figure 20-21-22].

133 of 1052 20-21-9 T870 Service Manual

CYLINDER (TILT) (CONT’D) Figure 20-21-27

Assembly (Cont'd)

Figure 20-21-25

3 1
1

4
2 P-85651B

Install the bushing (Item 1) [Figure 20-21-27] using a

P109554 driver tool and hammer.

NOTE: Lube chamfer on shaft with oil or grease

before installing the collar.

NOTE: Clean and dry the threads before installing the

nut. Install the new nut from the kit.

Install the head (Item 1), collar (Item 2), piston (Item 3)
and nut (Item 4) [Figure 20-21-25].

Tighten the nut (Item 4) [Figure 20-21-25] to 1491 N•m

(1100 ft-lb) torque.

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

Figure 20-21-26

P106021

Using an Adjustable Gland Nut Wrench, tighten the head

(Item 1) [Figure 20-21-26] to 373 N•m (275 ft-lb) torque.

134 of 1052 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

AVOID INJURY OR DEATH

Always clean up spilled fuel or oil. Keep heat, flames,
2
sparks or lighted tobacco away from fuel and oil. 1
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

P-85570 (Front Accessory Panel).

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).

135 of 1052 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].

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.

136 of 1052 20-22-2 T870 Service Manual

CYLINDER (BOB-TACH) (CONT’D)

Parts Identification

1. Tube 8. Rod
2. Nut 9. Grease Fitting
3. Seal
4. O-ring
5. Piston
6. Spacer
7. Head

10

2
3
4
5

3
4

7
3
3

4
8

NA2603S

137 of 1052 20-22-3 T870 Service Manual

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

Disassembly 3 2 1
Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook

MEL1075 - Adjustable Gland Nut 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.

Figure 20-22-6
P16295

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

from the piston (Item 3) [Figure 20-22-8].
1
Figure 20-22-9

2
P-64451

Use an Adjustable Gland Nut Wrench to loosen the head

(Item 1) [Figure 20-22-6].

Figure 20-22-7
P101716
2
4 3 1
Remove the thin O-ring (Item 1) and the seal (Item 2)
[Figure 20-22-9] from the cylinder 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.

138 of 1052 20-22-4 T870 Service Manual

CYLINDER (BOB-TACH) (CONT’D)

Disassembly (Cont’d)

Figure 20-22-10

P-48040

Remove the wiper seal (Item 1) [Figure 20-22-10] from

the cylinder head.

Figure 20-22-11

P-48042

Remove the rod seal (Item 1) [Figure 20-22-11] from the

cylinder head.

139 of 1052 20-22-5 T870 Service Manual

CYLINDER (BOB-TACH) (CONT’D) Figure 20-22-13

Assembly
3 1
2
Use the following tools to assembly the cylinder:

MEL1396-1 - Universal Seal Expander

MEL1033 - Rod Seal Installation Tool
MEL1396-2 - Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench

Wash the cylinder parts in solvent and air dry them.

4
Inspect the cylinder parts for nicks, scratches or other
damage. Replace any damaged parts.
P16295
Always install new O-rings and seals during assembly.

Lubricate all O-rings and seals with hydraulic oil during Piston: Install the O-ring (Item 1) and seal (Item 2) on the
installation. piston (Item 3) [Figure 20-22-13].

Figure 20-22-12 NOTE: The piston center hole (Item 4) [Figure 20-22-
13] has a bevel on one end. The bevel goes
toward the rod.

Figure 20-22-14

P7424

Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-12]. N-22358

Allow the seal to stretch for 30 seconds before installing it

on the piston. Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for
approximately three minutes [Figure 20-22-14].

140 of 1052 20-22-6 T870 Service Manual

CYLINDER (BOB-TACH) (CONT’D) Figure 20-22-17

Assembly (Cont’d)

Figure 20-22-15

P7425

Install the rod seal in the head [Figure 20-22-17].

N-20612
Install the wiper seal with the wiper toward the outside of
the head.
Install the rod seal on the rod seal tool [Figure 20-22-15].
Figure 20-22-18
NOTE: During installation the spring side of the seal
must be toward the inside of the cylinder.

Figure 20-22-16 1

P101716

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

N-20613 22-18] on the cylinder head.

NOTE: Clean and dry the threads before installing the

Rotate the handles to collapse the rod seal [Figure 20- nut. Install the new nut from the seal kit.
22-16].

141 of 1052 20-22-7 T870 Service Manual

CYLINDER (BOB-TACH) (CONT’D)

Assembly (Cont’d)

Figure 20-22-19

3
2 4
1

P16294

Install the head (Item 1) and spacer (Item 2) [Figure 20-

22-19].

Install the piston (Item 3) [Figure 20-22-19].

Grease the piston where the nut contacts the piston. do

not get grease on the threads. Install the new nut (Item 4)
[Figure 20-22-19].

Tighten the nut to 190 N•m (140 ft-lb) torque.

Figure 20-22-20

P-64451

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

Using an Adjustable Gland Nut Wrench, tighten the head

(Item 1) [Figure 20-22-20] to 183 N•m (135 ft-lb) torque.

142 of 1052 20-22-8 T870 Service Manual

MAIN RELIEF VALVES Testing

Description

The main relief valve and auxiliary relief valve limit the
hydraulic system pressure by opening at a certain
WARNING
pressure and allowing the hydraulic oil to flow back to the
hydraulic reservoir. (See Hydraulic System on Page When the engine is running during service, the
SPEC-10-4.) driving and steering controls must be in neutral and
the parking brake engaged. Failure to do so can
Figure 20-30-1 cause injury or death.
W-2006-1209

The tools listed will be needed to do the following

procedure:

2 MEL1355-3 - Pressure gauge 34,5 MPa (345 bar) (5000

psi)
MEL1723 - Female Test Coupler
7246786 - Female Test Coupler
Hydraulic hose, approximately 1,5 m (5.0 ft), purchased
locally. Must be rated for pressures above 34,5 MPa (345
bar) (5000 psi).
1
Figure 20-30-2
P107749A

The relief valves are adjustable and located on the

1 3
hydraulic control valve. The main relief valve (Item 1)
[Figure 20-30-1] is located below the spool linkages,
facing the front of the machine. The auxiliary relief valve
(Item 2) [Figure 20-30-1] is located on the top of the
control valve facing the left side of the machine.
2
4

P121789

Test ports have changed on the Main valve. If your test

port looks like (Item 2) use test coupler (Item 1). If your
test port looks like (Item 4) Use test coupler (Item 3)
[Figure 20-30-2].

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.

143 of 1052 20-30-1 T870 Service Manual

MAIN RELIEF VALVES (CONT’D) Figure 20-30-4

Testing (Cont’d)

WARNING 2

1
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 P107935

Figure 20-30-3 Connect the test coupler (Item 1) to the test port (Item 2)
[Figure 20-30-4].

1 Route the test gauge so it can be used in the operator

cab when lowered. Make sure the hose will not interfere
with any moving parts.

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

2.)

3 NOTE: Do not have any attachment connected to the

3 loader auxiliary quick couplers while testing.
2

P-43196D

Assemble the gauge (Item 1), hose (Item 2) and the

correct test coupler (Item 3) [Figure 20-30-3]. Tighten all
fittings.

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

144 of 1052 20-30-2 T870 Service Manual

MAIN RELIEF VALVES (CONT’D) Testing Auxiliary Relief Pressure

Testing (Cont’d) The auxiliary relief valve setting is 23,8 - 24,5 MPa (238 -
245 bar) (3450 - 3550 psi).
Enter the loader and engage the parking brake. Start the
engine. Figure 20-30-5

Increase the engine speed to full rpm and make sure the
hydraulic oil is at 60°C (140°F).

Testing Main Relief Pressure

The main relief valve setting is 27,2 - 27,9 MPa (272 -

279 bar) (3950 - 4050 psi).
2
NOTE: Do not have any bucket or attachment 1
connected to the loader.

Power loader lift arms down on the stops and monitor the
test gauge for the relief pressure setting.
NA3267
If the relief pressure is not correct, stop the engine and
adjust the relief valve. (See Main Relief Valve Adjustment
on Page 20-30-4.) Press the auxiliary hydraulics button (Item 1) [Figure 20-
30-5] to activate the auxiliary hydraulics.

NOTE: The auxiliary indicator (Item 2) [Figure 20-30-

5] will illuminate when activated.

Figure 20-30-6
Right
Steering
Lever
Control

P107006B

Move the front auxiliary hydraulic switch (Item 1) [Figure

20-30-6] to the left or right and monitor the test gauge for
the relief pressure setting.

If the relief pressure is not correct, stop the engine and

adjust the relief valve. (See Auxiliary Relief Valve
Adjustment on Page 20-30-5.)

Stop the machine and exit the loader.

145 of 1052 20-30-3 T870 Service Manual

MAIN RELIEF VALVES (CONT’D) Main Relief Valve Removal And Installation

Main Relief Valve Adjustment

Figure 20-30-7
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
2
Raise the operator cab. (See Raising on Page 10-30-1.)

Clean the area around the control valve.

1 NOTE: This procedure is for loaders equipped with

P107744 SJC or SCPA controls. The main relief valve is
located in the same place on all of the loaders.
Loosen the locknut (Item 1) [Figure 20-30-7].
Figure 20-30-8
Turn the adjustment screw (Item 2) [Figure 20-30-7] in or
out until the pressure is correct. Turning the 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. 1

P107743

Remove the main relief valve (Item 1) [Figure 20-30-8].

146 of 1052 20-30-4 T870 Service Manual

MAIN RELIEF VALVES (CONT’D) Auxiliary Relief Valve Adjustment

Main Relief Valve Removal And Installation (Cont’d) NOTE: This procedure is for loaders equipped with
SJC or SCPA controls. The auxiliary relief
Figure 20-30-9 valve is located in the same place on all of the
loaders.

Figure 20-30-10

1 2

P107745A 1

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

P107747
[Figure 20-30-9] from the relief valve.

Clean the relief valve in clean solvent. Use air pressure to Loosen the locknut (Item 1) [Figure 20-30-10].
dry the valve.
Turn the adjustment screw (Item 2) [Figure 20-30-10] in
Install a new O-ring (Item 1) and back-up ring (Item 2) or out until the pressure is correct. Turning the screw in
[Figure 20-30-9]. Install the main relief valve and tighten. will increase pressure.

Installation: Tighten the relief valve to 51 - 62 N•m (38 - NOTE: If the correct pressure can not be reached,
45 ft-lb) torque. replace the auxiliary relief valve. Test the
pressure setting of the new relief valve.
Test the relief valve. (See Testing on Page 20-30-1.)

147 of 1052 20-30-5 T870 Service Manual

MAIN RELIEF VALVES (CONT’D) Figure 20-30-12

Auxiliary Relief Valve Removal And Installation

IMPORTANT 2
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 1
P107627
Raise the operator cab. (See Raising on Page 10-30-1.)

Clean the area around the control valve. Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-30-12] from the auxiliary relief valve.
NOTE: This procedure is for loaders equipped with
SJC or SCPA controls. The auxiliary relief Clean the relief valve in clean solvent. Use air pressure to
valve is located in the same place on all of the dry the valve.
loaders.
Install new O-rings (Item 1) and back-up ring (Item 2)
Figure 20-30-11 [Figure 20-30-12]. Install the relief valve and tighten.

Installation: Tighten the relief valve to 51 - 62 N•m (38 -

45 ft-lb) torque.

Test the relief valve. (See Testing on Page 20-30-1.)

P107746

Remove the auxiliary relief valve (Item 1) [Figure 20-30-

11].

148 of 1052 20-30-6 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC)

Description
DANGER
Figure 20-40-1

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
P107847A
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
The hydraulic control valve is located inside the main
frame on the right hand side, below the operator’s cab.

The hydraulic control valve is the hydraulic component

that uses spools to direct the flow of hydraulic fluid to the
WARNING
lift, tilt, and auxiliary functions.
Never work on a machine with the lift arms up unless
The lift and tilt functions in the hydraulic control valve are the lift arms are secured by an approved lift arm
operated using electronic control handles / levers that support device. Failure to use an approved lift arm
send an electronic signal to the electronic actuators to support device can allow the lift arms or attachment
move the lift and tilt spools in the control valve. to fall and cause injury or death.
W-2059-0598
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 handles / levers. The activated
solenoid sends pilot pressure oil to one side of the spool
and forces the spool to shift.
IMPORTANT
The hydraulic control valve is designed with two relief When repairing hydrostatic and hydraulic systems,
valve ports. The main relief valve is used on the 800, 700, clean the work area before disassembly and keep all
and 600 series loaders. The auxiliary relief valve is parts clean. Always use caps and plugs on hoses,
standard on the 800 series and may be present on the tubelines and ports to keep dirt out. Dirt can quickly
700 and 600 series. damage the system.
I-2003-0888

The relief valves are adjustable and located on the

hydraulic control valve. The main relief valve port is
adjacent to the actuator side. The auxiliary relief valve
port is located on top of the control valve between the
case drain and load check valves.

149 of 1052 20-40-1 T870 Service Manual

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

Removal And Installation

1
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.)

Drain the hydraulic reservoir. (See Removing And

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

Remove the control panel. (See Removal And Installation

on Page 50-100-1.)
P115820
NOTE: Mark all tubelines, hoses, and electrical
connections for correct installation.
Remove the two bolts (Item 1) [Figure 20-40-3] securing
the fuel inlet assembly mount.
Cap and plug all hydraulic connection points
when tubelines or hoses are removed.
Figure 20-40-4
Clean area around control valve.

Open rear door.

1
Figure 20-40-2

3
2

P115821

1 2 Reposition the clamp (Item 1) and remove the fuel fill

hose (Item 2) [Figure 20-40-4] from the tank.

P121903

Disconnect the harness (Item 1) [Figure 20-40-2] from

the bottom of the filter.

Remove the two bolts (Item 2) and reposition the fuel

filter assembly (Item 3) [Figure 20-40-2].

150 of 1052 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 3

1 1

P109152A

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

P-115822
Disconnect the tubeline (Item 2) and remove the control
valve coupler (Item 3) [Figure 20-40-7].
The fixed end main valve hose assembly is connected to
a fixed end fitting on the control valve. The hose is routed Figure 20-40-8
to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can
only be removed by first removing it from the fitting (Item
1) [Figure 20-40-5].

Figure 20-40-6
1

1
2 1
2

P109151C

Disconnect the hose (Item 1) [Figure 20-40-8] that

1 routes from the control valve to the drain manifold.

P109151B Disconnect the hose (Item 2) [Figure 20-40-8] that

routes from the control valve to the brake valve.

Disconnect the wire harness connectors (Item 1) [Figure

20-40-6] from the control valve.

Remove the tie-strap (Item 2) [Figure 20-40-6].

151 of 1052 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
2
1

P109120A

Disconnect the two tubelines (Item 1) [Figure 20-40-11]

P109129A that route from the control valve to the front auxiliary
hydraulics.

Disconnect the hose (Item 1) [Figure 20-40-9] that Figure 20-40-12

routes from the control valve to the inlet fitting of the
hydraulic pump.

Disconnect the hose (Item 2) [Figure 20-40-9] that

routes from the control valve to the fan motor.

Figure 20-40-10

1
P-90273
2

Remove the tubeline clamp (Item 1) [Figure 20-40-12].

P109119A

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

routes from the top of the control valve to the hydraulic
filter.

Disconnect the hose (Item 2) [Figure 20-40-10] that

routes from the control valve to the high flow fitting on the
hydraulic pump.

152 of 1052 20-40-4 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-15

Removal And Installation (Cont'd)

Figure 20-40-13

2
1

P109103A

1 Disconnect the hose (Item 1) [Figure 20-40-15] that

P109122A routes from the bottom of the control valve to the outlet
fitting of the hydraulic pump.

Disconnect the three tubelines (Item 1) [Figure 20-40- Disconnect the hose (Item 2) [Figure 20-40-15] that
13] that route from the control valve to the junction block routes from the control valve to the junction block at the
at the rear of the loader. rear of the machine.

Figure 20-40-14 Figure 20-40-16

P109101B P109124B

Disconnect the lift arm bypass drain hose (Item 1) Support the control valve and remove the two bolts (Item
[Figure 20-40-14] from the control valve. 1) [Figure 20-40-16].

Remove the control valve from the loader.

153 of 1052 20-40-5 T870 Service Manual

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

Actuator Removal And Installation (In Loader)

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 1

P107802A
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Remove the two screws (Item 1) [Figure 20-40-18] 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.

Figure 20-40-17 Figure 20-40-19

1
2
1

P109131 P109133A

Unplug the actuator connectors (Item 1) [Figure 20-40- Pull the actuator (Item 1) [Figure 20-40-19] away from
17] from the loader harness. the control valve.

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

20-40-19] from the actuator and spool.

Remove the actuator from the hydraulic control valve.

Repeat procedure for the second actuator.

NOTE: The calibration procedure must be followed

when replacing a lift or tilt actuator. (See Lift
And Tilt Calibration (SJC) on Page 60-160-4.)

154 of 1052 20-40-6 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Actuator Removal And Installation (Out Of Loader)

Actuator Removal And Installation (In Loader) Remove the control valve from the loader.
(Cont’d)
Figure 20-40-21
Figure 20-40-20
1

1
2
1

P107802
P-54568

Remove the two mount bolts (Item 1) [Figure 20-40-21]

Remove the O-ring (Item 1) [Figure 20-40-20] on the from the tilt actuator.
face of the actuator.
Installation: Tighten the mounting bolts to 10,2 - 11,3
Inspect the linkage pin (Item 2) [Figure 20-40-20] and N•m (90 - 100 in-lb) torque.
replace as needed.
Figure 20-40-22
NOTE: Repeat this procedure to remove the lift
actuator.

P107803

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

22] away from the control valve.

Pull the actuator away from the control valve [Figure 20-
40-22].

155 of 1052 20-40-7 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-25

Actuator Removal And Installation (Out of Loader)

(Cont’d)

Figure 20-40-23 1

1
P107804

1
Remove the two mount bolts (Item 1) [Figure 20-40-25]
from the lift actuator.
P107808
Installation: Tighten the mounting bolts to 10,2 - 11,3
N•m (90 - 100 in-lb) torque.
Using a punch and a hammer, remove the actuator
linkage pin (Item 1) [Figure 20-40-23] from the actuator Figure 20-40-26
and the tilt spool.

Remove the actuator and linkage pin from the valve.

Figure 20-40-24

1 1

P107805

2
Slide the actuator mount bracket (Item 1) [Figure 20-40-
26] away from the control valve.
P-54340
Pull the actuator away from the control valve [Figure 20-
40-26].
Remove the O-ring (Item 1) [Figure 20-40-24] on the
face of the actuator.

Inspect the linkage pin (Item 2) [Figure 20-40-24] and

replace as needed.

156 of 1052 20-40-8 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-29

Actuator Removal And Installation (Out Of Loader) 4

(Cont’d)

Figure 20-40-27
2

1 3
P107807A

1
NOTE: The two long bolts (Item 1) are used to mount
the lift actuator (Item 2) [Figure 20-40-29] to
P107806 the control valve. The two short bolts (Item 3)
are used to mount the tilt actuator (Item 4)
[Figure 20-40-29].
Using a punch and a hammer, remove the actuator
linkage pin (Item 1) [Figure 20-40-27] from the actuator Installation: Tighten the mounting bolts to 10,2 - 11,3
and the tilt spool. N•m (90 - 100 in-lb) torque (Item 1) [Figure 20-40-29].

Remove the actuator and linkage pin from the valve.

Figure 20-40-28

P-54340

Remove the O-ring (Item 1) [Figure 20-40-28] on the

face of the actuator.

Inspect the linkage pin (Item 2) [Figure 20-40-28] and

replace as needed.

157 of 1052 20-40-9 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D)

Identification Chart

Figure 20-40-30

AR
C2 J2 C3
J4
E3 B3 E3
F2 G2
G1
D5 A3 D6
B2 A2
D3
E2
D4 C4

D1
H2
H3 D2
A1
E1
B1
F1 MR C1
H1
J3
J1
NA5825

ITEM DESCRIPTION ITEM DESCRIPTION

A1 Lift Cylinder Base End D6 Port Relief / Anti-Cavitation Valve (Auxiliary)
A2 Tilt Cylinder Base End 27579 kPa (276 bar) (4000 psi) (Optional)
A3 Auxiliary Hydraulics Female Coupler E1 Lift Spool Detent
B1 Lift Cylinder Rod End E2 Tilt Spool Centering Spring
B2 Tilt Cylinder Rod End E3 Auxiliary Spool / Centering Springs
B3 Auxiliary Hydraulics Male Coupler F1 Lift Spool
C1 Load Check F2 Tilt Spool
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 – 31026 kPa H3 BICS™ Lock Valve (Lift)
(310 bar) (4500 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End)
J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief / Anti-Cavitation Valve – 27579 kPa
J3 Lift Arm Bypass Orifice
(276 bar) (4000 psi)
Tilt (Base End) J4 Drain (Case)
D4 Port Relief / Anti-Cavitation Valve – 31026 kPa MR Main Relief Valve – 27579 kPa (276 bar)
(310 bar) (4500 psi) (4000 psi)
Tilt (Rod End) AR Auxiliary Relief Valve – 24132 kPa (241 bar)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary) (3500 psi)
27579 kPa (276 bar) (4000 psi) (Optional)

158 of 1052 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 20-40-31
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

1
Figure 20-40-33

P-90280

Support the mounting bracket (Item 1) [Figure 20-40-31].

Figure 20-40-32
1

2
P107848

Remove the charge tubeline (Item 1) [Figure 20-40-33]

from the BICS™ valve fitting on the top of the lift load
check valve.
1

P100202

Remove the two control valve mount bolts (Item 1)

[Figure 20-40-32].

Remove the two frame bolts (Item 2) [Figure 20-40-32]

Installation: Torque the two frame bolts (Item 2) [Figure

20-40-32] to 300 - 330 ft lb (406 - 447 N•m).

Remove the control valve bracket from the loader.

159 of 1052 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 20-40-36

Figure 20-40-34

P107850A

P107849
At the front side of the control valve locate and remove
the tilt section load check valve (Item 1) [Figure 20-40-
Remove the lift load check valve (Item 1) [Figure 20-40- 36].
34] and fitting from the top of the control valve.
At the front side of the control valve locate and remove
Installation: Lubricate the O-ring and threads and the auxiliary section load check valve (Item 2) [Figure
tighten to 68 - 94 N•m (50 - 70 ft-lb) torque. 20-40-36].

Figure 20-40-35 NOTE: The tilt and auxiliary load check valves are
interchangeable.

Figure 20-40-37
1
5

1
2
2

3 4
4
P107716

3
Remove the O-rings (Item 1) and back-up ring (Item 2)
P107624
[Figure 20-40-35].

Inspect the spring (Item 3) and the free movement load Remove the spring (Item 1) and poppet (Item 2) [Figure
check valve (Item 4) [Figure 20-40-35]. 20-40-37].

Inspect the orifice to make sure it is not plugged (Item 5) Inspect the orifice (Item 3) [Figure 20-40-37] in the
[Figure 20-40-35]. poppet to make sure it is not plugged.

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

37] and lubricate with oil before installing. Tighten the
plug to 51 - 61 N•m (38 - 45 ft-lb) torque.

160 of 1052 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 20-40-40

Figure 20-40-38

P107628A

P107628A
Remove the lift circuit port relief / anti-cavitation valve
and the port relief / anti-cavitation seat (Item 1) [Figure
At the back side of the control valve, remove the lift 20-40-40].
section anti-cavitation valve (Item 1) [Figure 20-40-38].
Figure 20-40-41
Figure 20-40-39

1
2 2

1
4

3 P107952
P107624

Remove the O-ring (Item 1) [Figure 20-40-41] from the

Remove the spring (Item 1) and poppet (Item 2) [Figure port relief / anti-cavitation relief valve.
20-40-39].
Inspect the port relief / anti-cavitation seat (Item 2)
Inspect the orifice (Item 3) [Figure 20-40-39] in the [Figure 20-40-41] for wear or damage and replace as
poppet to make sure it is not plugged. needed.

Installation: Install a new O-ring (Item 4) [Figure 20-40- Installation: Tighten the port relief / anti-cavitation seat
39] on the plug and lightly lubricate with oil before to 51 - 61 N•m (38 - 45 ft-lb) torque.
installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb)
torque. Installation: Replace O-ring, lightly lubricate with oil and
tighten the port relief / anti-cavitation relief valve to 51 -
61 N•m (38 - 45 ft-lb) torque.

161 of 1052 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 20-40-44

Figure 20-40-42

P107628A

P107628A
Remove the tilt port relief / anti-cavitation valve and the
port relief / anti-cavitation seat (Item 1) [Figure 20-40-
Remove the tilt port relief / anti-cavitation valve (Item 1) 44].
[Figure 20-40-42] from the base end of the tilt section.
Figure 20-40-45
Figure 20-40-43

1
1

P107952
P107629

Remove the O-ring (Item 1) [Figure 20-40-45] from the

Remove the O-ring (Item 1) [Figure 20-40-43] from the port relief / anti-cavitation relief valve.
port relief / anti-cavitation relief valve.
Inspect the port relief / anti-cavitation seat (Item 2)
Installation: Replace O-ring, lightly lubricate with oil and [Figure 20-40-45] for wear or damage and replace as
tighten the port relief / anti-cavitation relief valve to 51 - needed.
61 N•m (38 - 45 ft-lb) torque.
Installation: Tighten the port relief / anti-cavitation seat
to 51 - 61 N•m (38 - 45 ft-lb) torque.

Installation: Replace O-ring, lightly lubricate with oil and

tighten the port relief / anti-cavitation relief valve to 51 -
61 N•m (38 - 45 ft-lb) torque.

162 of 1052 20-40-14 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-48

Port Relief Valve Removal And Installation

Figure 20-40-46

P107628A

The control valve may be equipped with an optional

P107628A auxiliary port relief valve (Item 1) [Figure 20-40-48].

Remove the auxiliary port relief valve.

Remove the port relief plug (Item 1) [Figure 20-40-46]
from the auxiliary circuit of the control valve. Figure 20-40-49

Figure 20-40-47

P107629

P107630
Remove the O-ring (Item 1) [Figure 20-40-49] from the
auxiliary port relief valve.
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-40-47] from the port relief plug. Installation: Replace O-ring, lightly lubricate with oil and
tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Replace O-rings and back-up ring, lightly
lubricate with oil and tighten to 51 - 61 N•m (38 - 45 ft-lb)
torque.

163 of 1052 20-40-15 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-52

Port Relief Valve Removal And Installation (Cont’d)

Figure 20-40-50

P107628A

The control valve may be equipped with an optional

P107628A auxiliary port relief valve (Item 1) [Figure 20-40-52].

Remove the auxiliary port relief valve.

Remove the port relief plug (Item 1) [Figure 20-40-50]
from the auxiliary circuit of the control valve. Figure 20-40-53

Figure 20-40-51

2
P107629

P107630
Remove the O-ring (Item 1) [Figure 20-40-53] from the
auxiliary port relief valve.
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-40-51] from the port relief plug. Installation: Replace O-ring, lightly lubricate with oil and
tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Replace O-rings and back-up ring, lightly
lubricate with oil and tighten to 51 - 61 N•m (38 - 45 ft-lb)
torque.

164 of 1052 20-40-16 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-56

Plug Removal And Installation

Figure 20-40-54

P107632

At the bottom side of the control valve remove the plug

P107631A (Item 1) [Figure 20-40-56].

Figure 20-40-57
At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-54].

Figure 20-40-55

P107633

Remove the O-ring (Item 1) [Figure 20-40-57] from the

P107633 plug.

Installation: Replace O-ring, lightly lubricate with oil and

Remove the O-ring (Item 1) [Figure 20-40-55] from the tighten to 81,3 N•m (60 ft-lb) torque.
plug.

Installation: Replace O-ring, lightly lubricate with oil and

tighten to 81,3 N•m (60 ft-lb) torque.

165 of 1052 20-40-17 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 MEL1285 - Spring Tool
Page 20-40-6.)
Remove the end cap block from the control valve.
Figure 20-40-58
Figure 20-40-60

1 2 P107851A

P107853

Disconnect the tubeline (Item 1) [Figure 20-40-58] from

the end cap block. Remove the O-ring (Item 1) [Figure 20-40-60].

Remove the two end cap block mount screws (Item 2) Installation: Replace the O-ring, and lubricate lightly
[Figure 20-40-58]. with oil before installation of the end cap block.

Installation: Lubricate the screws and tighten to 10,4 - Figure 20-40-61

11,6 N•m (95 - 105 in-lb) torque.

Figure 20-40-59

1
P107753
1

P107852A Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-61] from the lift spool.

Remove the end cap block (Item 1) [Figure 20-40-59]

from the control valve.

166 of 1052 20-40-18 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-64

Lift Spool Removal And Installation (Cont'd)

Figure 20-40-62

1
P107756

1 Remove the lift spool assembly (Item 1) and O-ring (Item

P107854 2) [Figure 20-40-64] from the control valve.

Figure 20-40-65
Remove the four screws (Item 1) [Figure 20-40-62] from
the spool centering block.

Installation: Lubricate the screws and tighten to 10,4 -

11,6 N•m (95 - 105 in-lb) torque.

Figure 20-40-63

2 P107757

Remove the lift spool seal (Item 1) [Figure 20-40-65]

from the actuator end of the valve.
1

P107855

Remove the spool centering block (Item 1) and O-ring

(Item 2) [Figure 20-40-63] from the control valve.

Installation: Replace the O-ring (Item 2) [Figure 20-40-

63] and lubricate lightly with oil before installation of the
spool centering block.

167 of 1052 20-40-19 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-68

Lift Spool Disassembly And Assembly

Figure 20-40-66
1

P107647

Remove the bolt (Item 1) [Figure 20-40-68] holding the

P107740 centering spring to the spool.

Installation: Tighten the bolt to 10,4 - 11,6 N•m (95 - 105

Clamp the actuator end of the spool in a vise [Figure 20- in-lb) torque.
40-66].
Remove spring tool from the spring assembly.
NOTE: Protect spool before clamping in vise.
Figure 20-40-69
Figure 20-40-67

1 1
4

P-51776B
P107646

Inspect the adapter (Item 1), collar (Item 2), spring (Item
Install the spring tool (Item 1) [Figure 20-40-67] over the 3), and washer (Item 4) [Figure 20-40-69].
centering spring.

168 of 1052 20-40-20 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-72

Tilt Spool Removal And Installation

Remove the end cap block. (See End Cap Block

Removal And Installation on Page 20-40-18.)

Figure 20-40-70
2

P107769

1 Remove the tilt spool assembly (Item 1) and O-ring (Item

2) [Figure 20-40-72].
2
Figure 20-40-73
P107856

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

20-40-70] from the tilt spool.

Figure 20-40-71

P107770

Remove the spool seal (Item 1) [Figure 20-40-73].

P107769

Remove the O-ring (Item 1) [Figure 20-40-71].

Installation: Replace the O-ring and lubricate lightly with

oil before installation of the spool centering block.

169 of 1052 20-40-21 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-76

Tilt Spool Disassembly And Assembly

Figure 20-40-74 2 1
3

N-18944B

Inspect the adapter (Item 1), collar (Item 2), spring (Item
P107646 3), and washer (Item 4) [Figure 20-40-76].

Put the actuator end of the spool in the vise [Figure 20-
40-74].

NOTE: Protect spool before clamping in vise.

Install the spring tool (Item 1) [Figure 20-40-74] over the

centering spring.

Figure 20-40-75

P107647

Remove the bolt (Item 1) [Figure 20-40-75] holding the

centering spring to the spool.

Installation: Tighten the bolt to 10,4 - 11,6 N•m (95 - 105

in-lb) torque.

Remove the spring tool from the spring assembly.

170 of 1052 20-40-22 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-79

Auxiliary Spool Removal And Installation

Figure 20-40-77

2
1

2
P107760

1 Remove the spring (Item 1) and center spring retainer

P107758 (Item 2) [Figure 20-40-79] from the auxiliary spool.

NOTE: If the centering spring retainer (Item 2) [Figure

Remove the spring (Item 1) and center spring retainer 20-40-79] must be replaced, replace the
(Item 2) [Figure 20-40-77] from the auxiliary spool. retainer on the opposite end also.

NOTE: If the centering spring retainer (Item 2) [Figure Figure 20-40-80

20-40-77] must be replaced, replace the
retainer on the opposite end also.

Figure 20-40-78

2 1

P107761

1
Remove the spacer (Item 1) and O-ring (Item 2) [Figure
P107759 20-40-80] from the auxiliary spool.

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

20-40-78] from the auxiliary spool.

171 of 1052 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 20-40-82

Figure 20-40-81

1
2 2
1

P107847A

P107762
Remove the screws (Item 1) [Figure 20-40-82] from both
solenoids.
Remove the auxiliary spool (Item 1) [Figure 20-40-81].
Remove the solenoids (Item 2) [Figure 20-40-82].

Installation: Tighten the screws to 2,3 - 2,7 N•m (21.4 -

23.9 in-lb) torque.

Figure 20-40-83

P107798

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

[Figure 20-40-83] from the solenoid stem.

Use an ohmmeter to measure the solenoid coil

resistance.

The correct resistance for the coil is 5.1 ohm.

Installation: Lubricate and install new O-rings (Item 1)

and back-up rings (Item 2) [Figure 20-40-83].

172 of 1052 20-40-24 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-86

Solenoid Removal And Installation

Figure 20-40-84
1

P107857A

Remove the solenoid stem (Item 1) [Figure 20-40-86].

P107847A
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 20-40-84] from the
solenoid stem. Figure 20-40-87

Installation: Tighten the nut to 6 N•m (53 in-lb) torque.

Remove the solenoid coil (Item 2) [Figure 20-40-84].

3
Figure 20-40-85 2

N-18694

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

[Figure 20-40-87] 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 20-40-85] from both excessive wear.
ends of the solenoid coil.
NOTE: The screen (Item 3) [Figure 20-40-87] 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.

173 of 1052 20-40-25 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-90

Lock Valve Removal And Installation

Figure 20-40-88

1 2
P107937

The inside diameter of the BICS™ valve (Item 1) [Figure

P107858 20-40-90] is threaded for easier removal and installation.

Figure 20-40-91
Locate the two BICS™ lock valves: tilt circuit lock valve
(Item 1) and lift circuit lock valve (Item 2) [Figure 20-40-
88].
1 3
Figure 20-40-89
2

1
P107767

Remove the O-ring (Item 1) [Figure 20-40-91].

P107859 Remove and inspect the spring (Item 2) and BICS™

valve (Item 3) [Figure 20-40-91].

Remove the lift lock valve retaining cap (Item 1) [Figure

20-40-89] from the back of the control valve.

Installation: Lightly lubricate the lock valve retaining cap

O-ring and tighten to 75 - 81 N•m (55 - 60 ft-lb) torque.

174 of 1052 20-40-26 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Figure 20-40-93

Lock Valve Removal And Installation (Cont’d)

Figure 20-40-92

1
P107937

The inside diameter of the BICS™ valve (Item 1) [Figure

P107860A 20-40-93] is threaded for easier removal and installation.

Figure 20-40-94
Remove the tilt lock valve retaining cap (Item 1) [Figure
20-40-92] from the front of the control valve.

Installation: Lightly lubricate the lock valve retaining cap 1 3

O-ring and tighten to 75 - 81 N•m (55 - 60 ft-lb) torque.
2

P107767

Remove the O-ring (Item 1) [Figure 20-40-94].

Remove and inspect the spring (Item 2) and BICS™

valve (Item 3) [Figure 20-40-94].

175 of 1052 20-40-27 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D) Main Relief Valve Removal And Installation

Lift Arm Bypass Orifice Removal And Installation Figure 20-40-97

Figure 20-40-95

1 1
P107862A

P107861
Remove the main relief valve (Item 1) [Figure 20-40-97].

Remove the fitting (Item 1) [Figure 20-40-95] from the Figure 20-40-98
valve.

Figure 20-40-96

1
1

P107659

P-51437 Remove the O-rings (Item 1) [Figure 20-40-98] from the

main relief valve.

Inspect the lift arm bypass orifice (Item 1) [Figure 20-40- Installation: Replace O-rings, lightly lubricate with oil
96]. and tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.

NOTE: This orifice is not removable from the valve

casting.

176 of 1052 20-40-28 T870 Service Manual

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

Auxiliary Relief Valve Removal And Installation Figure 20-40-101

Figure 20-40-99

1
1

P107848

P107863A
Remove the tubeline (Item 1) [Figure 20-40-101].

Remove the auxiliary relief valve (Item 1) [Figure 20-40- Figure 20-40-102
99].

Figure 20-40-100

2
1

P107864

1
P107627 Remove the check valve fitting (Item 1) [Figure 20-40-
102] from the hydraulic control valve.

Remove the O-rings (Item 1) [Figure 20-40-100] and

back-up ring (Item 2) [Figure 20-40-100] from the
auxiliary relief valve.

Installation: Replace O-rings and back-up ring, lightly

lubricate with oil and tighten to 51 - 61 N•m (38 - 45 ft-lb)
torque.

177 of 1052 20-40-29 T870 Service Manual

HYDRAULIC CONTROL VALVE (SJC) (CONT’D)

Check Valve Removal And Installation (Cont’d)

Figure 20-40-103

P107625

Inspect the spring (Item 2) and poppet (Item 3) [Figure

20-40-103].

Remove the O-ring (Item 1) [Figure 20-40-103].

Installation: Replace O-ring, lightly lubricate with oil and

tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb) torque.

178 of 1052 20-40-30 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA)

Description
DANGER
Figure 20-41-1

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
P107865A
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
The hydraulic control valve is located inside the main
frame on the right hand side, below the operator’s cab.

The hydraulic control valve is the hydraulic component

that uses spools to direct the flow of hydraulic fluid to the
WARNING
lift, tilt, and auxiliary functions.
Never work on a machine with the lift arms up unless
The lift and tilt functions in the hydraulic control valve are the lift arms are secured by an approved lift arm
operated by linkage connected to the foot pedals. 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 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 is designed with two relief

IMPORTANT
valve ports. The main relief valve is used on the 800, 700,
and 600 series loaders. The auxiliary relief valve is When repairing hydrostatic and hydraulic systems,
standard on the 800 series and may be present on the clean the work area before disassembly and keep all
700 and 600 series. parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
The relief valves are adjustable and located on the damage the system.
I-2003-0888
hydraulic control valve. The main relief valve port is
adjacent to the spool linkages. The auxiliary relief valve
port is located on top of the control valve between the
case drain and load check valves.

179 of 1052 20-41-1 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-3

Removal And Installation

1
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.)

Drain the hydraulic reservoir. (See Removing And

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

Remove the control panel. (See Removal And Installation

on Page 50-100-1.)
P115820
NOTE: Mark all tubelines, hoses, and electrical
connections for correct installation.
Remove the two bolts (Item 1) [Figure 20-41-3] securing
the fuel inlet assembly mount.
Cap and plug all hydraulic connection points
when tubelines or hoses are removed.
Figure 20-41-4
Clean area around control valve.

Open rear door.

1
Figure 20-41-2

3
2

P115821

1 2 Move the hose clamp (Item 1) to the middle of the hose

(Item 2) [Figure 20-41-4] and place the fuel inlet
assembly off to the side.
P121903

Disconnect the harness (Item 1) [Figure 20-41-2] from

the bottom of the filter.

Remove the two bolts (Item 2) and reposition the fuel

filter assembly (Item 3) [Figure 20-41-2].

180 of 1052 20-41-2 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-7

Removal And Installation (Cont’d)

1
Figure 20-41-5

1
2

P109148B

Disconnect the hose (Item 1) [Figure 20-41-7] that

P-115822 routes from the control valve to the inlet fitting of the
hydraulic pump.

The fixed end main valve hose assembly is connected to Disconnect the hose (Item 2) [Figure 20-41-7] that
a fixed end fitting on the control valve. The hose is routed routes from the control valve to the fan motor.
to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can Figure 20-41-8
only be removed by first removing it from the fitting (Item
1) [Figure 20-41-5].

Figure 20-41-6 3

1
1
1

2
2

P109153A

3 1 Remove the tubeline clamp (Item 1) [Figure 20-41-8].

P109148A
Disconnect the tubeline (Item 2) and remove the control
valve coupler (Item 3) [Figure 20-41-8].
Disconnect the wire harness connectors (Item 1) [Figure
20-41-6] from the control valve.

Disconnect the hose (Item 2) [Figure 20-41-6] that

routes from the control valve to the drain manifold.

Disconnect the hose (Item 3) [Figure 20-41-6] that

routes from the control valve to the brake valve.

181 of 1052 20-41-3 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-11

Removal And Installation (Cont’d)

Figure 20-41-9

2 1

P-90273

Remove the tubeline clamp (Item 1) [Figure 20-41-11].

P109148C
Figure 20-41-12

Disconnect the hose (Item 1) [Figure 20-41-9] that

routes from the top of the control valve to the hydraulic 1
1
filter.

Remove the linkages (Item 2) [Figure 20-41-9] from the

control valve. (See Linkage Removal And Installation on
Page 50-90-2.)

Figure 20-41-10

P109121A

2 2 1
Disconnect the three tubelines (Item 1) [Figure 20-41-
12] that route from the control valve to the junction block
at the rear of the loader.

P109153C

Remove the tubeline clamp (Item 1) [Figure 20-41-10].

Disconnect the two tubelines (Item 2) [Figure 20-41-10]

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

182 of 1052 20-41-4 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-15

Removal And Installation (Cont’d)

Figure 20-41-13

1
P109124A

Support the control valve and remove the two bolts (Item
P109101A 1) [Figure 20-41-15].

Remove the control valve from the loader.

Disconnect the lift arm bypass drain hose (Item 1)
[Figure 20-41-13] from the control valve.

Figure 20-41-14

P109102A

Disconnect the hose (Item 1) [Figure 20-41-14] that

routes from the control valve to the junction block at the
rear of the machine.

Disconnect the hose (Item 2) [Figure 20-41-14] that

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

183 of 1052 20-41-5 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D)

Mount Bracket Removal And Installation

Figure 20-41-16

P-90280

Support the mounting bracket (Item 1) [Figure 20-41-16].

Figure 20-41-17

P100202

Remove the two control valve mount bolts (Item 1)

[Figure 20-41-17].

Remove the two frame bolts (Item 2) [Figure 20-41-17]

Installation: Torque the two frame bolts (Item 2) [Figure

20-41-17] to 406 - 447 N•m (300 - 330 ft-lb).

Remove the control valve bracket from the loader.

184 of 1052 20-41-6 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D)

Identification Chart

Figure 20-41-18

AR
C2 J2 C3
J4
B3 E3
F2 E3 G1
G2
D5 A3
D6
B2 A2 D3
E2
D4 F4 C4
D1 H2

D2
A1
H3 E1
B1
F3 MR
F1 H1 J1 J3
C1
NA5826

ITEM DESCRIPTION ITEM DESCRIPTION

A1 Lift Cylinder Base End D6 Port Relief / Anti-Cavitation Valve (Auxiliary)
A2 Tilt Cylinder Base End 27579 kPa (276 bar) (4000 psi) (Optional)
A3 Auxiliary Hydraulics Female Coupler E1 Lift Spool Detent
B1 Lift Cylinder Rod End E2 Tilt Spool Centering Spring
B2 Tilt Cylinder Rod End E3 Auxiliary Spool / Centering Springs
B3 Auxiliary Hydraulics Male Coupler F1 Lift Spool
C1 Load Check F2 Tilt Spool
C2 Load Check Valve Tilt Function F3 Lift Spool Lock Solenoid
C3 Load Check Valve Auxiliary Function F4 Tilt Spool Lock Solenoid
C4 Check Valve G1 Auxiliary Solenoid Stem
D1 Anti-Cavitation Valve G2 Auxiliary Solenoid Stem
Lift (Rod End) H1 BICS™ Solenoid
D2 Port Relief / Anti-Cavitation Valve – 31026 kPa H2 BICS™ Lock Valve (Tilt)
(310 bar) (4500 psi)
Lift (Base End) H3 BICS™ Lock Valve (Lift)
D3 Port Relief / Anti-Cavitation Valve – 27579 kPa J1 Inlet Fluid Flow (From Pump)
(276 bar) (4000 psi) J2 Outlet Fluid Flow (Return to Tank)
Tilt (Base End)
J3 Lift Arm Bypass Orifice
D4 Port Relief / Anti-Cavitation Valve – 31026 kPa
J4 Drain (Case)
(310 bar) (4500 psi)
Tilt (Rod End) MR Main Relief Valve – 27579 kPa (276 bar)
(4000 psi)
D5 Port Relief / Anti-Cavitation Valve (Auxiliary)
27579 kPa (276 bar) (4000 psi) (Optional) Auxiliary Relief Valve – 24132 kPa (241 bar)
AR
(3500 psi)

185 of 1052 20-41-7 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-20

Lift Load Check Valve Removal And Installation

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
damage the system.
I-2003-0888

P107867
Figure 20-41-19

Remove the lift load check valve (Item 1) [Figure 20-41-

20] 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.

Figure 20-41-21

1
5
P107866

Remove the charge tubeline (Item 1) [Figure 20-41-19] 2

from the BICS™ valve fitting on the top of the lift load
check valve.
3
4

P107716

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

[Figure 20-41-21].

Check the spring (Item 3) and the free movement load

check valve (Item 4) [Figure 20-41-21].

Inspect the orifice to make sure it is not plugged (Item 5)

[Figure 20-41-21].

186 of 1052 20-41-8 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-23

Load Check Valve Removal And Installation (Tilt And

Auxiliary)

Figure 20-41-22
1
2

2
4

1 3
P107624

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

20-41-23].
P107868A
Check the orifice (Item 3) [Figure 20-41-23] in the
poppet to make sure it is not plugged.
At the front side of the control valve locate and remove
the tilt section load check valve (Item 1) [Figure 20-41- Installation: Install a new O-ring (Item 4) [Figure 20-41-
22]. 23] and lubricate with oil before installing. Tighten the
plug to 51 - 61 N•m (38 - 45 ft-lb) torque.
At the front side of the control valve locate and remove
the auxiliary section load check valve (Item 2) [Figure
20-41-22].

NOTE: The tilt and auxiliary load check valves are

interchangeable.

187 of 1052 20-41-9 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 20-41-26

Figure 20-41-24

P107628A

P107628A
Remove the lift circuit port relief / anti-cavitation valve
and the port relief / anti-cavitation seat (Item 1) [Figure
At the back side of the control valve, remove the lift 20-41-26].
section anti-cavitation valve (Item 1) [Figure 20-41-24].
Figure 20-41-27
Figure 20-41-25

1 2
2

1
4

3
P107952
P107624

Remove the O-ring (Item 1) [Figure 20-41-27] from the

Remove the spring (Item 1) and poppet (Item 2) [Figure port relief / anti-cavitation relief valve.
20-41-25].
Inspect the port relief / anti-cavitation seat (Item 2)
Inspect the orifice (Item 3) [Figure 20-41-25] in the [Figure 20-41-27] for wear or damage and replace as
poppet to make sure it is not plugged. needed.

Installation: Install a new O-ring (Item 4) [Figure 20-41- Installation: Tighten the port relief / anti-cavitation seat
25] on the plug and lightly lubricate with oil before to 51 - 61 N•m (38 - 45 ft-lb) torque.
installing. Tighten the plug to 51 - 61 N•m (38 - 45 ft-lb)
torque. Installation: Replace O-ring, lightly lubricate with oil and
tighten the port relief / anti-cavitation relief valve to 51 -
61 N•m (38 - 45 ft-lb) torque.

188 of 1052 20-41-10 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 20-41-30

Figure 20-41-28

P107628A

P107628A
Remove the tilt port relief / anti-cavitation valve and the
port relief / anti-cavitation seat (Item 1) [Figure 20-41-
Remove the tilt port relief / anti-cavitation valve (Item 1) 30].
[Figure 20-41-28] from the base end of the tilt section.
Figure 20-41-31
Figure 20-41-29

1
1

P107952
P107629

Remove the O-ring (Item 1) [Figure 20-41-31] from the

Remove the O-ring (Item 1) [Figure 20-41-29] from the port relief / anti-cavitation relief valve.
port relief / anti-cavitation relief valve.
Inspect the port relief / anti-cavitation seat (Item 2)
Installation: Replace O-ring, lightly lubricate with oil and [Figure 20-41-31] for wear or damage and replace as
tighten the port relief / anti-cavitation relief valve to 51 - needed.
61 N•m (38 - 45 ft-lb) torque.
Installation: Tighten the port relief / anti-cavitation seat
to 51 - 61 N•m (38 - 45 ft-lb) torque.

Installation: Replace O-ring, lightly lubricate with oil and

tighten the port relief / anti-cavitation relief valve to 51 -
61 N•m (38 - 45 ft-lb) torque.

189 of 1052 20-41-11 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-34

Port Relief Valve Removal And Installation

Figure 20-41-32

P107628A

The control valve may be equipped with an optional

P107628A auxiliary port relief valve (Item 1) [Figure 20-41-34].

Remove the auxiliary port relief valve.

Remove the port relief plug (Item 1) [Figure 20-41-32]
from the auxiliary circuit of the control valve. Figure 20-41-35

Figure 20-41-33

1
1

2 P107629

P107630
Remove the O-ring (Item 1) [Figure 20-41-35] from the
port relief / anti-cavitation relief valve.
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-41-33] from the port relief plug. Installation: Replace O-ring, lightly lubricate with oil and
tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Replace O-rings and back-up ring, lightly
lubricate with oil and tighten to 51 - 61 N•m (38 - 45 ft-lb)
torque.

190 of 1052 20-41-12 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-38

Port Relief Valve Removal And Installation (Cont’d)

Figure 20-41-36

P107628A

The control valve may be equipped with an optional

P107628A auxiliary port relief valve (Item 1) [Figure 20-41-38].

Remove the auxiliary port relief valve.

Remove the port relief plug (Item 1) [Figure 20-41-36]
from the auxiliary circuit of the control valve. Figure 20-41-39

Figure 20-41-37

1
1

2 P107629

P107630
Remove the O-ring (Item 1) [Figure 20-41-39] from the
port relief valve.
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-41-37] from the port relief plug. Installation: Replace O-ring, lightly lubricate with oil and
tighten to 51 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Replace O-rings and back-up ring, lightly
lubricate with oil and tighten to 51 - 61 N•m (38 - 45 ft-lb)
torque.

191 of 1052 20-41-13 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-42

Plug Removal And Installation

Figure 20-41-40

1
1

P107632

At the bottom side of the control valve remove the plug

P107631A (Item 1) [Figure 20-41-42].

Figure 20-41-43
At the top side of the control valve, remove the plug (Item
1) [Figure 20-41-40].

Figure 20-41-41

P107633

Remove the O-ring (Item 1) [Figure 20-41-43] from the

P107633 plug.

Installation: Replace O-ring, lightly lubricate with oil and

Remove the O-ring (Item 1) [Figure 20-41-41] from the tighten to 81,3 N•m (60 ft-lb) torque.
plug.

Installation: Replace O-ring, lightly lubricate with oil and

tighten to 81,3 N•m (60 ft-lb) torque.

192 of 1052 20-41-14 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) End Cap Block Removal And Installation

Rubber Boot Removal And Installation Figure 20-41-46

Figure 20-41-44

1
2
1

1
P107772A

P-51506
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-41-46] from the
Remove the three screws (Item 1) [Figure 20-41-44] on end cap block.
the rubber boot retainer plate.
Figure 20-41-47
Installation: Lubricate the screws and tighten to 10,4 -
11,6 N•m (95 - 105 in-lb) torque.

Figure 20-41-45

1
1
1

P107865A

Disconnect the tubeline (Item 1) [Figure 20-41-47] from

P107664C the end cap block.

Remove the rubber boots (Item 1) from the retainer plate

(Item 2) [Figure 20-41-45].

193 of 1052 20-41-15 T870 Service Manual

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

End Cap Block Removal And Installation (Cont’d) The tool listed will be needed to do the following
procedure:
Figure 20-41-48
MEL1278 - Detent Tool
MEL1285 - Detent Spring Tool

Remove the end cap block from the control valve.

Figure 20-41-49

2
1 1
P107773A

Remove the end cap block mount screw (Item 1) [Figure

20-41-48].

Installation: Lubricate the screws and tighten to 10,4 -

P107776
11,6 N•m (95 - 105 in-lb) torque.

Remove the end cap block (Item 2) [Figure 20-41-48] Remove the O-ring (Item 1) [Figure 20-41-49].
from the control valve.
Installation: Replace and lubricate the O-ring lightly with
grease or oil before installation of the end cap block.

Figure 20-41-50

P107775

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

20-41-50] from the lift spool.

194 of 1052 20-41-16 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-53

Lift Spool And Detent Removal And Installation

(Cont’d)

Figure 20-41-51

P107846

1 NOTE: Do not remove the sleeve detent (Item 1) or

retaining ring (Item 2) [Figure 20-41-53] from
P107779 the spool centering block. If removed, the
sleeve detent must be inserted with the
original orientation.
Remove the four screws (Item 1) [Figure 20-41-51] from
the spool centering block. Figure 20-41-54

Figure 20-41-52

1
P107845A

P107778
NOTE: If removed, use the following for correct
installation: for a radius lift pattern machine,
Remove the spool centering block (Item 1) [Figure 20- align the radius side (Item 1) [Figure 20-41-54]
41-52]. so it faces the opening of the spool centering
block when seated. For a vertical lift pattern
Remove the O-ring (Item 2) [Figure 20-41-52]. machine, align the vertical side (Item 2)
[Figure 20-41-54] so it faces the opening when
seated. Install retaining ring over detent
sleeve.

195 of 1052 20-41-17 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-57

Lift Spool And Detent Removal And Installation

(Cont'd)

Figure 20-41-55

2
P107739

Clamp the linkage end of the spool in a vise [Figure 20-

1 41-57].
P107790
NOTE: Protect spool before clamping in vise.

Remove the lift spool assembly (Item 1) and O-ring (Item

2) [Figure 20-41-55].

Figure 20-41-56 IMPORTANT

The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284

Figure 20-41-58

1 2

P107757A

Remove the lift spool seal (Item 1) [Figure 20-41-56]

from the linkage end of the valve.

P107674A

Install the spring tool (Item 1) [Figure 20-41-58] over the

centering spring.

NOTE: Be careful when removing the detent adapter

(Item 2) [Figure 20-41-58] from the centering
spring, as it is under spring pressure.

196 of 1052 20-41-18 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-61

Lift Spool And Detent Removal And Installation

1
(Cont'd)

Figure 20-41-59

4
2
1

P107676

Remove the spring tool (Item 1) [Figure 20-41-61] from

2 the spring assembly.
P107674
Figure 20-41-62

Remove the spring assembly / spring tool (Item 1) from

the spool (Item 2) [Figure 20-41-59].
3 2 1
NOTE: The detent adapter has two detent balls (Item
3) held under pressure from a detent spring 4
(Item 4) [Figure 20-41-61]. Use care when
removing the detent adapter from the spring
assembly so the detent balls are retained.

Figure 20-41-60

P107677

1
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-41-62].

P107675

Remove the detent adapter (Item 1) [Figure 20-41-60]

from the spring assembly.

197 of 1052 20-41-19 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-65

Lift Spool And Detent Removal And Installation

(Cont'd)

Figure 20-41-63
1

N-18967

Clamp the collar (Item 1) [Figure 20-41-65] in a vise.

N-18918 Figure 20-41-66

Remove the stud from the end of the spool [Figure 20-
41-63].
3
Figure 20-41-64 2

P107677

15,2 mm Apply grease on all the detent component surfaces

(0.60 in) before assembly [Figure 20-41-66].

B-14712B Install the spring (Item 1) [Figure 20-41-66] and detent

balls (Item 2) [Figure 20-41-66] into the adapter (Item 3)
[Figure 20-41-66] and compress with the detent pliers
Install the stud and tighten until the other end of the stud (Item 1) [Figure 20-41-67].
is out about 15,2 mm (0.600 in) from the spool [Figure
20-41-64].

198 of 1052 20-41-20 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-69

Lift Spool And Detent Removal And Installation

(Cont'd)

Figure 20-41-67

P107674
1

Install the spring assembly to the lift spool hand tight

[Figure 20-41-69].
N-18968A
Remove the spring tool.

Install the detent adapter to the collar [Figure 20-41-67]. Check the alignment of the detent adapter and the
washer.
NOTE: The collar and the detent adapter are held
together by spring pressure when assembled Tighten the adapter to 10,4 - 11,6 N•m (95 - 105 in-lb)
to the lift spool not the detent balls. Hold the torque.
detent adapter and collar together to prevent
the detent balls and spring from falling out. NOTE: The adapter must fit in the center of the
washer.
Figure 20-41-68
Figure 20-41-70

P107675 3
P107790

Install the spring tool (Item 1) [Figure 20-41-68] over the

washer, spring, collar, and detent adapter. Lubricate and install a new O-ring (Item 1) [Figure 20-41-
70].

Lubricate and install a new O-ring (Item 2) [Figure 20-41-

70].

Install the lift spool assembly (Item 3) [Figure 20-41-70]

in the spool bore.

199 of 1052 20-41-21 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-73

Lift Spool And Detent Removal And Installation

(Cont'd)

Figure 20-41-71

1 2

P107775

2 Install a spacer (Item 2) and a new O-ring (Item 1)

[Figure 20-41-73] on the lift spool.
P107779
Figure 20-41-74

Install the spool centering block (Item 1) [Figure 20-41-

71]. 1
Install the four mounting screws (Item 2) [Figure 20-41-
71].

Installation: Lubricate the screws and tighten to 10,4 -

11,6 N•m (95 - 105 in-lb) torque.

Figure 20-41-72

P107776

1
Install a new O-ring (Item 1) [Figure 20-41-74] on the
control valve.

P107679A

Install a new spool seal (Item 1) [Figure 20-41-72] on the

linkage end of the valve.

200 of 1052 20-41-22 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-77

Lift Spool And Detent Removal And Installation

(Cont'd)

Figure 20-41-75

2 2

1
1

3
4 P107772A

Use an ohmmeter to measure the lock solenoid coils

resistance.
P107664C
The correct resistance for the coil is 16.02 - 19.58 ohm.

Install the end cap block (Item 1) and the mount bolt Installation: Install the lift spool (Item 1) and tilt spool
(Item 2) [Figure 20-41-75]. (Item 2) lock solenoids and tighten to 52 - 61 N•m (38 -
45 ft-lb) torque [Figure 20-41-77].
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-41-75].

Installation: Lubricate the screws and tighten to 10,4 -

11,6 N•m (95 - 105 in-lb) torque.

Figure 20-41-76

P107865A

Connect the tubeline (Item 1) [Figure 20-41-76].

201 of 1052 20-41-23 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-80

Tilt Spool Removal And Installation

Remove the end cap block. (See End Cap Block

Removal And Installation on Page 20-41-15.)
2
Figure 20-41-78

P107778

1 Remove the spool centering block (Item 1) [Figure 20-

2 41-80] from the control valve.

Installation: Replace the O-ring (Item 2) [Figure 20-41-

P107777 80] and lubricate the O-ring lightly with grease or oil
before installation of the spool centering block.

Remove the spacer (Item 1) and O-ring (Item 2) [Figure Figure 20-41-81
20-41-78] from the tilt spool.

Figure 20-41-79

1
P107780
1

P107779 Remove the tilt spool (Item 1) and O-ring (Item 2) [Figure
20-41-81].

Remove the four screws (Item 1) [Figure 20-41-79] from Installation: Replace the O-ring (Item 2) [Figure 20-41-
the spool centering block. 81] and lubricate the O-ring lightly with grease or oil
before installation of the spool centering block.
Installation: Lubricate the screws and tighten to 10,4 -
11,6 N•m (95 - 105 in-lb) torque.

202 of 1052 20-41-24 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-84

Tilt Spool Removal And Installation (Cont'd)

Figure 20-41-82

P107647

Remove the bolt (Item 1) [Figure 20-41-84] holding the

P107781 centering spring to the spool.

Installation: Tighten the bolt to 10,4 - 11,6 N•m (95 - 105

Remove the tilt spool seal (Item 1) [Figure 20-41-82]. in-lb) torque.

Assembly: Always use a new spool seal. Remove the spring tool from the spring assembly.

Figure 20-41-83 Figure 20-41-85

2 1
3

1
4

P107646 N-18944B

Put the linkage end of the spool in the vise [Figure 20- Inspect the adapter (Item 1), collar (Item 2), spring (Item
41-83]. 3), and washer (Item 4) [Figure 20-41-85].

NOTE: Protect spool before clamping in vise.

Install the spring tool (Item 1) [Figure 20-41-83] over the

centering spring.

203 of 1052 20-41-25 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-87

Auxiliary Spool Removal And Installation

Figure 20-41-86

1
3 2
1 4
2

P107783

3 Remove the spring (Item 1) and center spring retainer

P107782 (Item 2) [Figure 20-41-87] from the auxiliary spool.

Remove the spacer (Item 3) and O-ring (Item 4) [Figure

Remove the spring (Item 1) and center spring retainer 20-41-87] from the auxiliary spool.
(Item 2) [Figure 20-41-86] from the auxiliary spool.
NOTE: If the centering spring retainer (Item 2) [Figure
Remove the spacer (Item 3) and O-ring (Item 4) [Figure 20-41-87] must be replaced, replace the
20-41-86] from the auxiliary spool. retainer on the opposite end also.

NOTE: If the centering spring retainer (Item 2) [Figure Figure 20-41-88

20-41-86] must be replaced, replace the
retainer on the opposite end also.

P107784

Remove the auxiliary spool (Item 1) [Figure 20-41-88].

204 of 1052 20-41-26 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Solenoid Removal And Installation

Auxiliary Solenoid Removal And Installation Figure 20-41-91

Figure 20-41-89
1
2

1
2

1
P107869A

P107870A
Remove the nut (Item 1) [Figure 20-41-91] from the
solenoid stem.
Remove the screws (Item 1) [Figure 20-41-89] from both
solenoids. Installation: Tighten the nut to 6 N•m (53 in-lb) torque.

Remove the solenoids (Item 2) [Figure 20-41-89] from Remove the solenoid coil (Item 2) [Figure 20-41-91].
the control valve.
Figure 20-41-92
Installation: Tighten the screws to 2,3 - 2,7 N•m (21.4 -
23.9 in-lb) torque.
1
Figure 20-41-90
1

2 N-18693A

Remove the O-rings (Item 1) [Figure 20-41-92] from both

P107798 ends of the solenoid coil.

Use an ohmmeter to measure the solenoid coil

Remove the O-rings (Item 1) and back-up rings (Item 2) resistance.
[Figure 20-41-90] from the solenoid stem.
The correct resistance for the coil is 9.8 ohm.
Use an ohmmeter to measure the solenoid coil
resistance.

The correct resistance for the coil is 5.1 ohm.

205 of 1052 20-41-27 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-94

Solenoid Removal And Installation (Cont’d)

Figure 20-41-93
3
2

N-18694

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

P107870A [Figure 20-41-94] from the stem.

Clean all parts in solvent and dry with compressed air.

Remove the solenoid stem (Item 1) [Figure 20-41-93].
Inspect all parts for wear and replace any showing
Installation: Lubricate the O-rings and tighten the stem excessive wear.
to 27 - 33 N•m (20 - 24 ft-lb) torque.
NOTE: The screen (Item 3) [Figure 20-41-94] may be
cleaned with solvent. If it is torn or worn,
replace the solenoid valve

206 of 1052 20-41-28 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-97

Lock Valve Removal And Installation

Figure 20-41-95

2
1

1
P107937

The inside diameter of the BICS™ valve (Item 1) [Figure

P107785 20-41-97] is threaded for easier removal and installation.

Figure 20-41-98
Locate the two BICS™ lock valves: tilt circuit lock valve
(Item 1) and lift circuit lock valve (Item 2) [Figure 20-41-
95].
1 3
Figure 20-41-96
2

P107767

Remove the O-ring (Item 1) [Figure 20-41-98].

P107786 Remove and inspect spring (Item 2) and BICS™ valve

(Item 3) [Figure 20-41-98].

Remove the lift lock valve (Item 1) [Figure 20-41-96]

from the back of the control valve.

Installation: Lightly lubricate the lock valve retaining cap

O-ring and tighten to 75 - 81 N•m (55 - 60 ft-lb) torque.

207 of 1052 20-41-29 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Figure 20-41-101

Lock Valve Removal And Installation (Cont’d)

Figure 20-41-99

2
1
P107937

The inside diameter of the BICS™ valve (Item 1) [Figure

P107788 20-41-101] is threaded for easier removal and
installation.

Remove the lift spool lock solenoid (Item 1) [Figure 20- Figure 20-41-102
41-99].

Remove the tilt spool lock solenoid (Item 2) [Figure 20-

41-99]. 1 3
2
Installation: Lubricate the O-rings and tighten the spool
lock solenoids to 52 - 61 N•m (38 - 45 ft-lb) torque.

Figure 20-41-100

P107767

Remove the O-ring (Item 1) [Figure 20-41-102].

Remove and inspect the spring (Item 2) and BICS™

1
valve (Item 3) [Figure 20-41-102].

P107789

Remove the tilt lock valve (Item 1) [Figure 20-41-100]

from the front of the control valve.

Installation: Lightly lubricate the lock valve retaining cap

O-ring and tighten to 75 - 81 N•m (55 - 60 ft-lb) torque.

208 of 1052 20-41-30 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Main Relief Valve Removal And Installation

Lift Arm Bypass Orifice Removal And Installation Figure 20-41-105

Figure 20-41-103

P107787
1
P107866
Remove the main relief valve (Item 1) [Figure 20-41-
105].
Remove the fitting (Item 1) [Figure 20-41-103] from the
valve. Figure 20-41-106

Figure 20-41-104

P-51463

P-51437
Remove the O-rings (Item 1) [Figure 20-41-106] from the
main relief valve.
Check the lift arm bypass orifice (Item 1) [Figure 20-41-
104]. Installation: Replace O-ring, lightly lubricate with oil and
tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
NOTE: This orifice is not removable from the valve
casting.

209 of 1052 20-41-31 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D) Check Valve Removal And Installation

Auxiliary Relief Valve Removal And Installation Figure 20-41-109

Figure 20-41-107

P107866

P107870A
Remove the tubeline (Item 1) [Figure 20-41-109].

Remove the auxiliary relief valve (Item 1) [Figure 20-41- Figure 20-41-110
107].

Figure 20-41-108

1
2

P107786
1

P107627 Remove the check valve fitting (Item 1) [Figure 20-41-

110] from the hydraulic control valve.

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

[Figure 20-41-108] from the auxiliary relief valve.

Installation: Replace O-rings and back-up ring, lightly

lubricate with oil and tighten to 52 - 61 N•m (38 - 45 ft-lb)
torque.

210 of 1052 20-41-32 T870 Service Manual

HYDRAULIC CONTROL VALVE (SCPA) (CONT’D)

Check Valve Removal And Installation (Cont’d)

Figure 20-41-111

P107625

Inspect the spring (Item 2) and poppet (Item 3) [Figure

20-41-111].

Remove the O-ring (Item 1) [Figure 20-41-111].

Installation: Replace O-ring, lightly lubricate with oil and

tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb) torque.

211 of 1052 20-41-33 T870 Service Manual

212 of 1052 20-41-34 T870 Service Manual
LIFT ARM BYPASS CONTROL VALVE Testing

Description Figure 20-50-1

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 1

turning the knob (Item 1) [Figure 20-50-1] clockwise 1/4
turn and pulling on the valve knob. 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.

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.

213 of 1052 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) and
unless supported by an approved lift arm remove the jam nut (Item 2) [Figure 20-50-2] from the
support. Replace if damaged. valve shaft.
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.

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

214 of 1052 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.
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.

215 of 1052 20-50-3 T870 Service Manual

216 of 1052 20-50-4 T870 Service Manual
HYDRAULIC PUMP NOTE: When testing the hydraulic flow of a machine,
hoses must be at least 19 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 tester.
hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the Install a hydraulic tester (Item 1) [Figure 20-60-1] onto
engine. the front auxiliary quick couplers.

The hydraulic pump is a combination of gear pumps that This procedure will require one operator in the cab and
provide hydraulic flow to several hydraulic systems. one operator running the tester.

The hydraulic pump has a dedicated charge pump. This Start the engine and run at low idle rpm. Press the
supplies flow to the hydraulic fan motor and charge Auxiliary hydraulics button. Engage the front auxiliary
pressure to the hydrostatic pump. with the trigger on the right handle or joystick. Make sure
the tester is connected correctly. If no flow is indicated on
A seal kit is available to service the hydraulic pump. If any the tester, the hoses are connected wrong. With the
of the main components of the pump are damaged, the hoses connected correctly, increase the engine speed to
entire pump must be replaced. full rpm*.

Pump Test At Quick Couplers Warm the fluid to 60°C (140°F) by turning the restrictor
control clockwise on the tester so it reads about 6,9 MPa
(68,9 bar) (1000 psi).

WARNING NOTE: DO NOT EXCEED 25,5 MPa (255,1 bar) (3700

psi).
Put jackstands under the front axles and rear corners
Turn the restrictor control (Item 2) [Figure 20-60-1] on
of the frame before running the engine for service.
the tester counterclockwise to obtain free flow, the flow
Failure to use jackstands can allow the machine to
should be approximately 87 - 91 L/min (23 - 24 U.S.
fall or move and cause injury or death.
W-2017-0286
gpm). Start turning the restrictor clockwise, causing more
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 MPa (237,9 -
MEL1744, MEL10003 or TWX-RFIK200-S-6 Flow Meter 241,3 bar) (3450 - 3500 psi). At 23,8 - 24 MPa (237,9 -
MEL10006 - Fitting Kit 241,3 bar) (3450 - 3500 psi) the flow should be at 0 L/min
(0 U.S. gpm). Turn the restrictor (Item 2) [Figure 20-60-1]
Lift and block the loader. (See Procedure on Page 10-10- counterclockwise to free flow. Shut the auxiliary
1.) hydraulics off.

Figure 20-60-1 If flow and pressure specifications are not obtained, go to

Direct Pump Testing. (See Direct Pump Test (Standard
1 Section) on Page 20-60-2.)

*Refer to (See Hydraulic System on Page SPEC-10-4.)

for system relief pressure and full rpm.

P106632

217 of 1052 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 - Remote Start Tool Kit

MEL1744, MEL10003 or TWX-RFIK200-S-6 Flow Meter 2
MEL10006 - Fitting Kit

WARNING 1

P106429
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) that comes from
fall or move and cause injury or death. the gear pump and connects to the control valve fitting
W-2017-0286
(Item 2) [Figure 20-60-2].

Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-3
1.)

Raise the lift arms and install an approved lift arm

support device. (See Installing on Page 10-20-2.)

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.
P106631
W-2059-0598

Raise the operator cab. (See Raising on Page 10-30-1.) 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.
7217666 on Page 10-61-1.)

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

218 of 1052 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

%=
FREE FLOW (L/min [U.S. gpm])

A low percentage may indicate a failed pump.

*Refer to (See Hydraulic System on Page SPEC-10-4.)

for system relief pressure and full rpm.

219 of 1052 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:
1
MEL1563 - Remote Start Tool Kit
MEL1744, MEL10003 or TWX-RFIK200-S-6 Flow Meter
MEL10006 - Fitting Kit

WARNING
P115778A
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.)

Raise the lift arms and install an approved lift arm

support device. (See Installing on Page 10-20-2.)

2 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
P106631
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. (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 -
7217666 on Page 10-61-1.)

220 of 1052 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*.

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.

221 of 1052 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.

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 1
to fall and cause injury or death.
W-2059-0598
1
1

DANGER 1

P-115824

Disconnect and cap the four hoses (Item 1) [Figure 20-

60-6] from the hydraulic pump.

P-90328 Remove the Power Bob-Tach block if equipped. (See

Removal And Installation on Page 20-120-4.)
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
unless supported by an approved lift arm
support. Replace if damaged. 1
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, P107837F
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Disconnect and cap the outlet hoses (Item 1) [Figure 20-
60-7] from the hydraulic pump.

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 10-20-2.)

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

222 of 1052 20-60-6 T870 Service Manual

HYDRAULIC PUMP (CONT’D) Later Models

Removal And Installation (Cont’d) Figure 20-60-9

Earlier Models

Figure 20-60-8
2

1
1

2 P114386

3
Remove the bracket mounting bolt / nut (Item 1) [Figure
P107837E 20-60-9].

Installation: Tighten the bolt / nut to 34 - 38 N•m (25 - 28

Remove the two mounting bolts (Item 1), nut (Item 2) and
ft-lb) torque.
mounting plate (Item 3) [Figure 20-60-8] from the
hydraulic pump.
Figure 20-60-10
Remove the hydraulic pump (Item 4) [Figure 20-60-8]
from the loader.

Installation: Tighten the mounting bolts to 75 - 85 N•m

(55 - 60 ft-lb) torque.

Installation: Tighten nut (Item 2) [Figure 20-60-8] to 38

N•m (28 ft-lb) torque.

P106594A

Remove the two mounting bolts (Item 2) [Figure 20-60-9]

and [Figure 20-60-10].

Installation: Tighten the bolts to 75 - 85 N•m (55 - 60 ft-

lb) torque.

Remove the hydraulic pump.

223 of 1052 20-60-7 T870 Service Manual

HYDRAULIC PUMP (CONT’D)

Removal And Installation (Cont’d)

Figure 20-60-11

P-43940 P-43938A

Replace the O-ring (Item 1) [Figure 20-60-11] on the

hydraulic pump.

Reverse the removal procedure to install the hydraulic

pump.

224 of 1052 20-60-8 T870 Service Manual

HYDRAULIC PUMP (CONT’D) Crank the engine for 15 seconds, then stop for at least 30
seconds. Again, crank the engine for 15 seconds.
Hydraulic Pump Startup Remove the starter bypass tool.

NOTE: This procedure is necessary to prevent a dry Start the loader from the operator’s cab and run the
startup of the hydraulic pump. engine at low idle for 1 - 2 minutes without operating the
hydraulics.
Fill the system with hydraulic fluid. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
Figure 20-60-12 arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
of cylinder stroke.

With the loader parked on a level surface and lift arms

down, check and fill the hydraulic reservoir as required.
1 Check for hydraulic leaks.

P100685

Figure 20-60-13

P115825

Attach a push button starter switch (MEL1712) (Item 1)

[Figure 20-60-12] to the starter terminal S (Item 1) and
the positive battery cable (Item 2) [Figure 20-60-13].

225 of 1052 20-60-9 T870 Service Manual

HYDRAULIC PUMP (CONT’D)

Parts Identification

Figure 20-60-14
1. Bolt
2. Charge Pump End Section
3. Section Seal
4. Wear Plate
5. Charge Pump Center Section
6. Idler Gear
7. Drive Gear
8. Dowel Pin
9. Spline Shaft
10. Load Seal
11. Preload Seal
12. Center Section
13. Auxiliary Pump Center Section
14. Auxiliary Pump End Section
15. Shaft Seal
8 7

9
10

3 2
4

4 6 5
8
3
11
9
8

12
3
4

6 13
8
4
11 10
15 3

14

P-66540

226 of 1052 20-60-10 T870 Service Manual

HYDRAULIC PUMP (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 20-60-10.) for proper placement of components
along with the information below.

Assembly: Tighten the eight pump housing bolts (Item 1)

[Figure 20-60-14] to 50 N•m (37 ft-lb) torque.

NOTE: Position the wear plate (Item 4) [Figure 20-60-

14] as shown with the bronze side toward the
gears on all wear plates.

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.

227 of 1052 20-60-11 T870 Service Manual

228 of 1052 20-60-12 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 6894,8
The high flow hydraulic pump has an additional pump kPa (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 25510,6 kPa (255 bar) (3700
from a button on the panel in the cab. psi).

A seal kit is available to service the hydraulic pump. If any Turn the restrictor control (Item 2) [Figure 20-61-1] on
of the main components of the pump are damaged, the the tester counterclockwise to obtain free flow, the flow
entire pump must be replaced. should be approximately 140 - 144 L/min (37 - 38 U.S.
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
The tools listed will be needed to do the following 21373,8 kPa (213,7 bar) (3100 psi). At approximately
procedure: 21373,8 kPa (213,7 bar) (3100 psi) the flow should start
decreasing rapidly until the pressure reaches 23787,0 -
MEL1744, MEL10003 or TWX-RFIK200-S-6 Flow Meter 24131,7 kPa (237,9 - 241,3 bar) (3450 - 3500 psi). At
MEL10006 - Fitting Kit 23787,0 - 24131,7 kPa (237,9 - 241,3 bar) (3450 - 3500
psi) the flow should be at 0 L/min (0 U.S. gpm). Turn the
Figure 20-61-1 restrictor (Item 2) [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-10-4.)

for system relief pressure and full rpm.

P106632

NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19 mm (3/4 inch) 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).

229 of 1052 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 7217666 - Remote Start Tool

MEL1744, MEL10003 or TWX-RFIK200-S-6 Flow Meter-
Hydraulic Tester 2
MEL10006 - Fitting Kit

WARNING 1

P106429

Put jackstands under the front axles and rear corners

of the frame before running the engine for service. Disconnect the OUTLET hose (Item 1) [Figure 20-61-2]
Failure to use jackstands can allow the machine to that comes from the gear pump, and connects to the
fall or move and cause injury or death. control valve.
W-2017-0286

Figure 20-61-3
Lift and block 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 10-20-2.)

2 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
P106631
to fall and cause injury or death.
W-2059-0598
Connect the INLET hose (Item 1) [Figure 20-61-3] from
Raise the operator cab. (See Raising on Page 10-30-1.) the tester to the OUTLET hose (Item 1) [Figure 20-61-2]
of the pump. Connect the OUTLET hose (Item 2) [Figure
Connect the Remote Start Tool. (See REMOTE START 20-61-3] from the tester to the control valve fitting (Item
TOOL KIT - MEL1563 on Page 10-60-1.) or (See 2) [Figure 20-61-2] on the control valve.
REMOTE START TOOL (SERVICE TOOL) KIT -
7217666 on Page 10-61-1.)

NOTE: The control panel is shown removed for photo

clarity.

230 of 1052 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 7217666 - Remote Start Tool
tester, the hoses are connected wrong. With the hoses MEL1744, MEL10003 or TWX-RFIK200-S-6 Flow Meter
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 6894,8 kPa (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 Failure to use jackstands can allow the machine to
hydraulics, the light will come ON. Pull the trigger on the fall or move and cause injury or death.
right handle or joystick for fluid flow to the quick coupler W-2017-0286
(fluid pressure will go over main relief). Record the
highest pressure (psi) and flow (L/min [U.S. gpm]). The Lift and block the loader. (See Procedure on Page 10-10-
high 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
FREE FLOW (L/min [U.S. gpm]) support device. (See Installing on Page 10-20-2.)

A low percentage may indicate a failed pump.

*Refer to (See Hydraulic System on Page SPEC-10-4.)

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 -
7217666 on Page 10-61-1.)

231 of 1052 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 4136,9 kPa (41,4 bar) (600
psi). DO NOT exceed 8273,7 kPa (82,7 bar) (1200 psi).
Open the restrictor control and record the free flow (L/min
1 [U.S. gpm]) at full rpm*.

Turn the restrictor down to system operating pressure

approximately 6894,8 kPa (68,9 bar (1000 psi). DO NOT
EXCEED 8273,7 kPa (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])
P115778A

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
Figure 20-61-5 rpm.

2 1

P106631

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

232 of 1052 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 device. Failure to use an approved lift arm
support device. (See Installing on Page 10-20-2.)
support device can allow the lift arms or attachment
to fall and cause injury or death.
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 7217666 - Remote Start Tool

MEL1744, MEL10003 or TWX-RFIK200-S-6 Flow Meter
MEL10006 - Hydraulic Test Kit

Lift and block the loader. (See Procedure on Page 10-10-

1.)

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 -
7217666 on Page 10-61-1.)

233 of 1052 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 6894,8 kPa (68,9 bar) (1000
Direct Pump Test (High Flow Section) (Cont'd) psi).

Figure 20-61-7 NOTE: DO NOT EXCEED 25510,6 kPa (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
24131,7 kPa (241,3 bar) (3500 psi) and 25510,6 kPa
(255,1 bar) (3700 psi).

2 If pressure readings are not obtained go to the High Flow

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
P109134 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)
[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.

2
1

P106631

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*.

234 of 1052 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 40-20-6.) Remove the plug (Item 2) [Figure 20-61-10] located on
the bottom of the high flow relief valve.
Figure 20-61-9
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.

235 of 1052 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 40-20-6.)

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.

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.

236 of 1052 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
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 1
P-45462

Remove the solenoid nut (Item 1) [Figure 20-61-16].

Replace the O-rings (Item 1) and back-up ring (Item 2)
Remove the solenoid (Item 2) [Figure 20-61-16]. [Figure 20-61-18].

Installation: Tighten the solenoid nut to 5 - 8 N•m (48 -

72 in-lb).

237 of 1052 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.

WARNING Figure 20-61-19

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 1
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598 1
1

DANGER 1

P-115824

Disconnect and cap the inlet hoses (Item 1) [Figure 20-

61-19] from the front of the hydraulic pump.

Remove the Power Bob-Tach block (if equipped). (See

P-90328 Removal And Installation on Page 20-120-4.)

AVOID DEATH Figure 20-61-20

• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. 1
• 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 P107837G
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
Disconnect and cap the hoses (Item 1) [Figure 20-61-20]
damage the system.
I-2003-0888
from the back of the hydraulic pump.

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 10-20-2.)

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

238 of 1052 20-61-10 T870 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) Figure 20-61-23

Removal And Installation (Cont’d)

Figure 20-61-21

1
2

1
P-43940 P-43938A

Replace the O-ring (Item 1) [Figure 20-61-23] on the

P114386 hydraulic pump.

Reverse the procedure for installation.

Remove the bracket mounting bolt / nut (Item 1) [Figure
20-61-21].

Installation: Tighten the bolt / nut to 34 - 38 N•m (25 - 28

ft-lb) torque.

Figure 20-61-22

P106594A

Remove the two mounting bolts (Item 2) [Figure 20-61-

21] and [Figure 20-61-22].

Installation: Tighten the bolts to 75 - 85 N•m (55 - 60 ft-

lb) torque.

Remove the hydraulic pump.

239 of 1052 20-61-11 T870 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT’D) Crank the engine for 15 seconds, then stop for at least 30
seconds. Again, crank the engine for 15 seconds.
Hydraulic Pump Startup Remove the starter bypass tool.

NOTE: This procedure is necessary to prevent a dry Start the loader from the operator’s cab and run the
startup of the hydraulic pump. engine at low idle for 1 - 2 minutes without operating the
hydraulics.
Fill the system with hydraulic fluid. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
Figure 20-61-24 arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
of cylinder stroke.

With the loader parked on a level surface and lift arms

down, check and fill the hydraulic reservoir as required.
1 Check for hydraulic leaks.

P100685

Figure 20-61-25

P115850

Attach a push button starter switch (MEL1712) (Item 1)

[Figure 20-61-24] to the starter terminal S (Item 1) and
the positive battery cable (Item 2) [Figure 20-61-25].

240 of 1052 20-61-12 T870 Service Manual

HYDRAULIC PUMP (HIGH FLOW) (CONT’D)

Parts Identification

Figure 20-61-26

21

1. Stem
22
2. Valve
5 3. Wear Plate
4 4. Seal Section
3
6 5. Rear Housing
6. Bolt
7. Preload 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
8 9
7 16. Gear Set
23 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

241 of 1052 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.

Assembly: Tighten the eight pump housing bolts (Item 6)

[Figure 20-61-26] to 50 N•m (37 ft-lb) torque.

NOTE: Position the wear plate (Item 3) [Figure 20-61-

26] as shown with the bronze side toward the
gears on all wear plates.

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.

The relief valve and the solenoid can be

replaced along with the O-rings and back-up
rings.

242 of 1052 20-61-14 T870 Service Manual

HYDRAULIC / HYDROSTATIC FILTERS Housing Removal And Installation

Description

The hydraulic / hydrostatic filters help to remove

contaminants from the fluid when the hydraulic /
DANGER
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

gear pumps including oil returning from the main valve.

The charge flow filter removes contaminants after the P-90328

charge pump.
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

Raise the lift arms and install an approved lift arm

support device. (See Installing on Page 10-20-2.)

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

Drain the fluid from the reservoir. (See Removing And

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

243 of 1052 20-70-1 T870 Service Manual

HYDRAULIC / HYDROSTATIC FILTERS (CONT’D) Figure 20-70-3

Housing Removal And Installation (Cont’d)

Figure 20-70-1 1

2
1
P115774

Remove the two bolts (Item 1) [Figure 20-70-3].

P121308
Remove the hydraulic / hydrostatic filter housing from the
loader.
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-

70-1] from the hydraulic / hydrostatic filter housing.

Figure 20-70-2

P115827

Remove and plug the three hoses (Item 1) [Figure 20-

70-2] from the bottom of the hydraulic / hydrostatic filter
housing.

244 of 1052 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.

The hydraulic fluid reservoir is located behind the 1

operator’s cab under the rear grille on the right side of the
loader.

Removal And Installation

P115753
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
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.
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

P115773

Remove the clamp and the hose (Item 1) [Figure 20-80-

1].

245 of 1052 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

P121074A

Remove the hydraulic fluid reservoir breather cap (Item

1) [Figure 20-80-4] from the reservoir.

Figure 20-80-4

P121073A

Remove the hydraulic fluid screen (Item 1) [Figure 20-

80-4] from the reservoir.

Wash the screen in clean solvent and air dry, before

replacing.

246 of 1052 20-80-2 T870 Service Manual

OIL COOLER

Removal And Installation

The oil cooler and radiator are removed from the loader
as a unit. (See Radiator / Oil Cooler Removal And
Installation on Page 70-60-1.)

247 of 1052 20-90-1 T870 Service Manual

248 of 1052 20-90-2 T870 Service Manual
BUCKET POSITION VALVE Figure 20-100-1

Description

The bucket position valve is an option that allows the

operator to hold the attachment at the same angle from 3
the ground to maximum lift height without using the tilt
function.

The bucket position valve is mounted to the inside lower

right rear side of the loader frame.

See Hydraulic Schematic for more circuit information. 1 2

Solenoid Removal And Installation

P121903

IMPORTANT Disconnect the harness (Item 1) [Figure 20-100-1] from

the bottom of the filter.

When repairing hydrostatic and hydraulic systems, Remove the two bolts (Item 2) and reposition the fuel
clean the work area before disassembly and keep all filter assembly (Item 3) [Figure 20-100-1].
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly Figure 20-100-2
damage the system.
I-2003-0888
1

P-90328

AVOID DEATH
P115820
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. Remove the two bolts (Item 1) [Figure 20-100-2].
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409

Drain the hydraulic reservoir. (See Removing And

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

249 of 1052 20-100-1 T870 Service Manual

BUCKET POSITION VALVE (CONT’D) NOTE: Engine removed for photo clarity.

Solenoid Removal And Installation (Cont’d) Electric fuel pump removed for photo clarity.

Figure 20-100-3 Figure 20-100-5

3
1

1 P101161
P115828

Disconnect the wire harness connector (Item 1) [Figure

Remove the clamp / hose (Item 1) [Figure 20-100-3]
20-100-5] from the bucket position shut-off solenoid.
from the filler neck.
Disconnect and cap the two tubelines (Item 2) [Figure
Figure 20-100-4
20-100-5].

Remove the solenoid nut, coil, and stem (Item 3) from the
bucket positioning valve [Figure 20-100-5].
1
Installation: Put oil on O-rings and back-up rings and
tighten the solenoid stem to 40,7 - 50,2 N•m (31 - 37 ft-lb)
torque.

Installation: Tighten the solenoid nut to 8 N•m (6 ft-lb)

torque. Overtightening may cause valve failure.
2
Figure 20-100-6

P115821

Reposition the clamp (Item 1) and remove the fuel fill 1

hose (Item 2) [Figure 20-100-4] from the tank. 2

Cover the fuel tank inlet.

N-18191

Inspect the solenoid stem and replace the O-rings (Item

1) and the back-up ring (Item 2) [Figure 20-100-6].

250 of 1052 20-100-2 T870 Service Manual

BUCKET POSITION VALVE (CONT’D) Figure 20-100-8

Solenoid Testing
1
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
P115820

Remove the two bolts (Item 1) [Figure 20-100-8].

Figure 20-100-9

P-90328

AVOID DEATH
• Disconnecting or loosening any hydraulic 1
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

Drain the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-120-2.)
P115828
Figure 20-100-7
Remove the clamp / hose (Item 1) [Figure 20-100-9]
from the filler neck.

1 2

P121903

Disconnect the harness (Item 1) [Figure 20-100-7] from

the bottom of the filter.

Remove the two bolts (Item 2) and reposition the fuel

filter assembly (Item 3) [Figure 20-100-7].

251 of 1052 20-100-3 T870 Service Manual

BUCKET POSITION VALVE (CONT’D) Figure 20-100-12

Removal And Installation (Cont'd)

Figure 20-100-10
1

4 3

2 P101157

Disconnect and cap the tilt base inlet hose (Item 1), the
P115821 tilt rod inlet hose (Item 2), the lift rod inlet hose (Item 3),
and the lift base inlet hose (Item 4) [Figure 20-100-12]
that route from the control valve.
Reposition the clamp (Item 1) and remove the fuel fill
hose (Item 2) [Figure 20-100-10] from the tank.
Figure 20-100-13
Cover the fuel tank inlet.

NOTE: Engine removed for photo clarity.

Mark all hoses and tubelines for correct

installation.

Figure 20-100-11

2
1
P-90189A

Disconnect and cap the tilt cylinder hose (Item 1) and the
tilt cylinder base end hose (Item 2) [Figure 20-100-13]
from the valve block.

1 P101161

Disconnect the electric solenoid connector (Item 1)

[Figure 20-100-11].

252 of 1052 20-100-4 T870 Service Manual

BUCKET POSITION VALVE (CONT’D) Disassembly And Assembly

Removal And Installation (Cont'd) Figure 20-100-16

Figure 20-100-14

2
1 3

2
2

1 P-90192

P-90197A
Remove the solenoid nut (Item 1), coil (Item 2), and the
stem (Item 3) [Figure 20-100-16].
Disconnect and cap the lift base outlet hose and tubeline
(Item 1) and the lift rod outlet hose and tubeline (Item 2) Assembly: Tighten the nut to a maximum of 8 N•m (6 ft-
[Figure 20-100-14] that route from the lift cylinders. lb) torque. Overtightening may cause valve failure.

Figure 20-100-15 Assembly: Put oil on O-rings and back-up rings and
tighten the solenoid stem to 40,7 - 50,2 N•m (31 - 37 ft-lb)
torque.

Figure 20-100-17

1
1

P101159

Remove the mounting bolts (Item 1) [Figure 20-100-15].

P-90195
Remove the bucket position valve from the loader.

Remove the flow adjustment valve and O-ring (Item 1)

[Figure 20-100-17].

Assembly: Tighten the flow adjustment valve to 36,6 -

48,8 N•m (27 - 36 ft-lb) torque.

253 of 1052 20-100-5 T870 Service Manual

BUCKET POSITION VALVE (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-100-18

3
1

P-90194

Remove the tilt cylinder check valve (Item 1), spring (Item
2), and plug (Item 3) [Figure 20-100-18]. Inspect for
wear and replace as needed.

Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64

ft-lb) torque.

Figure 20-100-19

1
2 3

P-90193

Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-100-19]. Inspect for wear and
replace as needed.

Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64

ft-lb) torque.

254 of 1052 20-100-6 T870 Service Manual

REAR AUXILIARY DIVERTER VALVE Figure 20-110-2

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 P100765

Figure 20-110-1
Use a test meter to measure coil resistance [Figure 20-
110-2]. Solenoid coils do not have polarity. Correct
resistance for the solenoid coil with a pigtail connector is
4.6 - 5.7 ohm.

Figure 20-110-3

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.
P100763
Replace the test meter with 12 volt power. You can see
and hear the spool shift.
Use a test meter to measure coil resistance [Figure 20-
110-3]. Solenoid coil wires do not have polarity. Correct
resistance for the solenoid coil with molded connector is
8.1 - 9.9 ohm.

255 of 1052 20-110-1 T870 Service Manual

REAR AUXILIARY DIVERTER VALVE (CONT’D) Figure 20-110-5

Removal And Installation

1

DANGER

P121524
P-90328

AVOID DEATH Disconnect and cap the hoses (Item 1) [Figure 20-110-
• Disconnecting or loosening any hydraulic 5].
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. Figure 20-110-6
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm GREEN OR
support. Replace if damaged. YELLOW BROWN
D-1009-0409

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 10-20-2.)
GREEN OR
YELLOW
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.) WHITE
P121547A

Figure 20-110-4
Disconnect the harness connectors [Figure 20-110-6]
from the auxiliary valve. The wires have color coded
cable ties attached to them for identification.
2

2 2

P121527

Disconnect and cap the tubeline (Item 1) and hoses (Item

2) [Figure 20-110-4]

256 of 1052 20-110-2 T870 Service Manual

REAR AUXILIARY DIVERTER VALVE (CONT’D) Disassembly And Assembly

Removal And Installation (Cont’d) Figure 20-110-8

Figure 20-110-7

1
P100760
2
P121522
Figure 20-110-9

Remove the three bolts (Item 1) and remove the valve

(Item 2) [Figure 20-110-7]

P-48752

Clean the diverter valve to remove dirt before

disassembly. Valve ports are labeled for correct
assembly.

Several plugs (Item 1) [Figure 20-110-8] and [Figure 20-

110-9] are located all over the diverter valve and can be
removed for clean out purposes.

Assembly: Put oil on the O-rings and back-up rings.

Tighten to 13,6 N•m (10 ft-lb) torque.

257 of 1052 20-110-3 T870 Service Manual

REAR AUXILIARY DIVERTER VALVE (CONT’D) Figure 20-110-12

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

P100761
Figure 20-110-10

Figure 20-110-13

2
1 2

P100761

P-48757
Figure 20-110-11

Remove the differential sensing valve (Item 1) [Figure

20-110-12] and [Figure 20-110-13] from diverter valve
and replace the O-rings and back-up rings (Item 2)
[Figure 20-110-13].
2
2 2
Assembly: Put oil on the O-rings and back-up rings.
1 Tighten to 68 - 75 N•m (50 - 55 ft-lb) torque.

P-48756

Remove the shuttle valve (Item 1) [Figure 20-110-10]

and [Figure 20-110-11] from diverter valve and replace
the O-rings and back-up rings (Item 2) [Figure 20-110-
11].

Assembly: Put oil on the O-rings and back-up rings.

Tighten to 14 - 16 N•m (10 - 12 ft-lb) torque.

258 of 1052 20-110-4 T870 Service Manual

REAR AUXILIARY DIVERTER VALVE (CONT’D) Figure 20-110-16

Disassembly And Assembly (Cont'd)

Figure 20-110-14 1

P100762
1

NOTE: Before removing the solenoid coils mark the

P-48753 coils for proper alignment.

Remove the nut (Item 1) [Figure 20-110-16] from the

Figure 20-110-15 solenoid valve stem.

Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)

torque.
1
Figure 20-110-17

P-48754

Remove the relief valve (Item 1) [Figure 20-110-14] and

[Figure 20-110-15] from the diverter valve and replace
the O-rings and back-up rings (Item 2) [Figure 20-110-
P100764
15].

Assembly: Put oil on the O-rings and back-up rings. Remove the solenoid valve coils (Item 1) [Figure 20-110-
Tighten to 27 - 34 N•m (20 - 25 ft-lb) torque. 17].

259 of 1052 20-110-5 T870 Service Manual

REAR AUXILIARY DIVERTER VALVE (CONT’D) Figure 20-110-19

Disassembly And Assembly (Cont'd)

Figure 20-110-18

1
1 2
2

P-48762

Figure 20-110-20
P100764A

NOTE: Before removing the solenoid coils mark the

coils for proper alignment.

Remove the nuts (Item 1) and solenoid coils (Item 2)

[Figure 20-110-18] 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-

110-19] and [Figure 20-110-20] and replace the O-rings
and back-up rings (Item 2) [Figure 20-110-20].

Assembly: Put oil on the O-rings and back-up rings.

Tighten to 27 - 34 N•m (20 - 25 ft-lb) torque.

260 of 1052 20-110-6 T870 Service Manual

REAR AUXILIARY DIVERTER VALVE (CONT’D) Figure 20-110-23

Disassembly And Assembly (Cont'd)

Figure 20-110-21

P-48765

Remove the plug (Item 1) [Figure 20-110-23].

P-48763A
Assembly: Tighten the plug to 51,5 N•m (38 ft-lb) torque.

Figure 20-110-22 Figure 20-110-24

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-
110-21] and [Figure 20-110-22] and replace the O-rings 24] for dirt and debris.
and back-up rings (Item 2) [Figure 20-110-22].
Assembly: Tighten the orifice to 29,8 N•m (22 ft-lb)
Assembly: Put oil on the O-rings and back-up rings. torque.
Tighten to 41 - 47 N•m (30 - 35 ft-lb) torque.

261 of 1052 20-110-7 T870 Service Manual

REAR AUXILIARY DIVERTER VALVE (CONT’D) Figure 20-110-27

Disassembly And Assembly (Cont'd)

Figure 20-110-25

1 1

P100767

Remove the plugs (Item 1) [Figure 20-110-27].

P-48765
Assembly: Tighten the plug to 19 N•m (14 ft-lb) torque.

Remove the plug (Item 1) [Figure 20-110-25]. Inspect cartridges, check valves, solenoid valves and
sealing washers for contamination or damage. Wash all
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 rings.
Figure 20-110-26
Inspect diverter valve cavities for contamination. Wash
valve in clean solvent. Use air pressure to dry.

P-48786

Remove the orifice (Item 1) [Figure 20-110-26].

Assembly: Tighten the orifice to 4,5 N•m (3.3 ft-lb)

torque.

262 of 1052 20-110-8 T870 Service Manual

BOB-TACH (POWER) BLOCK

Description

The power Bob-Tach is an option that allows the operator

to hydraulically control the Bob-Tach levers for mounting
and dismounting the attachments.

The power Bob-Tach is operated by a switch on the right

switch panel.

The power Bob-Tach block is mounted on the right side of

the machine in front of the engine on the back side of the
hydraulic pump.

263 of 1052 20-120-1 T870 Service Manual

BOB-TACH (POWER) BLOCK (CONT’D) Figure 20-120-2

Testing Relief Valve

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 P106674
from a physician familiar with this injury.
W-2072-0807
Disconnect the hose (Item 1) [Figure 20-120-2] from the
cylinder base end port.

Figure 20-120-3
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

The following tools are required for this procedure:

MEL1355 hydraulic test kit.

Figure 20-120-1
P122238

Install the gauge (Item 1) [Figure 20-120-3] between the

hose and cylinder base end port and tighten.

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

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

(Front Accessory Panel).

Record the pressure reading. The pressure relief valve

should be set at 241 bar (3500 psi).
P122237

Tilt the Bob-Tach forward, parallel to the floor [Figure 20-

120-1].

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

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

264 of 1052 20-120-2 T870 Service Manual

BOB-TACH (POWER) BLOCK (CONT’D)

Testing Relief Valve (Cont’d)

Figure 20-120-4

P122229

NOTE: Relief valve removed from block for photo

clarity.

If adjustment is required loosen the jam nut (Item 1) and

turn the adjusting screw (Item 2) [Figure 20-120-4]
clockwise to increase pressure or counterclockwise to
decrease pressure.

Test the relief valve setting after adjustment has been

made.

265 of 1052 20-120-3 T870 Service Manual

BOB-TACH (POWER) BLOCK (CONT’D) NOTE: After repairing a machine that required the
power Bob-Tach valve electrical connectors
Removal And Installation to be disconnected, inspect the loader to
make sure the Bob-Tach wedges function
correctly. If the wedges do not function per
the information in the Operation &
WARNING Maintenance Manual, the electrical
connectors will have to be switched between
the two Bob-Tach valve coils. Do a final
Never work on a machine with the lift arms up unless
inspection to verify the wedges function
the lift arms are secured by an approved lift arm
correctly.
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
Lift and block the loader. (See Procedure on Page 10-10-
to fall and cause injury or death.
W-2059-0598
1.)

Raise the lift arms and install an approved lift arm

support device. (See Installing on Page 10-20-2.)

DANGER 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.)

Figure 20-120-5

P-90328

AVOID DEATH 1
• 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

P122161

Disconnect the two wire connectors (Item 1) [Figure 20-

IMPORTANT 120-5] from the solenoid coils.

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

266 of 1052 20-120-4 T870 Service Manual

BOB-TACH (POWER) BLOCK (CONT’D)

Removal And Installation (Cont'd)

Figure 20-120-6

2 2

P122162

Disconnect and cap the hose (Item 1) [Figure 20-120-6]

from block.

Disconnect and cap the hoses (Item 2) [Figure 20-120-6]

from block.

Figure 20-120-7

1 1

1
1

P122157

Remove the four mounting bolts (Item 1) [Figure 20-120-

7].

Installation: Tighten the mounting bolts to 48 - 54 N•m

(35 - 40 ft-lb) torque.

Remove the power Bob-Tach block.

267 of 1052 20-120-5 T870 Service Manual

BOB-TACH (POWER) BLOCK (CONT’D) Figure 20-120-9

Disassembly And Assembly

IMPORTANT
3
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
damage the system.
I-2003-0888 2

4 P122197
Figure 20-120-8

Remove plug (Item 1), spring (Item 2) and spool (Item 3)

[Figure 20-120-9] and inspect. Replace damaged parts
as needed.

Installation: Tighten the plug to 67,8 N•m (50 ft-lb)

torque.
1 Replace the O-ring (Item 4) [Figure 20-120-9] on the
plug.

1 Figure 20-120-10

P122196

Do not remove these plugs (Item 1) [Figure 20-120-8].

NOTE: Do not remove the expander plugs in block

(total of 11). A new Power Bob-Tach valve will
be required if tampered with. All other plugs
can be removed.

P122198

NOTE: Mark the solenoid coil orientation for

installation.

Remove the coil nut (Item 1) [Figure 20-120-10].

Installation: Tighten the solenoid coil valve stem nut to

6,8 N•m (5 ft-lb) torque.

268 of 1052 20-120-6 T870 Service Manual

BOB-TACH (POWER) BLOCK (CONT’D) Figure 20-120-13

Disassembly And Assembly (Cont'd)

2
Figure 20-120-11

3 P122201

Replace the O-rings (Item 1) and the back-up rings (Item

1
P122199 2) [Figure 20-120-13].

Figure 20-120-14
Remove the first solenoid coil (Item 1), the spacer (Item
2) and the second solenoid coil (Item 3) [Figure 20-120-
11].

Figure 20-120-12

2
1
P122202

1 Remove the fitting (Item 2) [Figure 20-120-12] and

replace the O-ring (Item 1) [Figure 20-120-14].
P122200

Remove the solenoid coil stem (Item 1) [Figure 20-120-

12].

Installation: Tighten the solenoid stem to 27,14 N•m

(20 ft-lb) torque.

269 of 1052 20-120-7 T870 Service Manual

BOB-TACH (POWER) BLOCK (CONT’D) Figure 20-120-17

Disassembly And Assembly (Cont'd)

Figure 20-120-15

P122206
1

Replace the O-ring (Item 1) and remove the screened

P122203 orifice (Item 2) [Figure 20-120-17]. Inspect and replace
as needed.

Remove the plug (Item 1) [Figure 20-120-15] and Figure 20-120-18

replace the O-ring.

Installation: Tighten the plug to 30 N•m (22 ft-lb) torque.

Figure 20-120-16 1

P122205

1
Remove the plug (Item 1) [Figure 20-120-18].

P122205 Installation: Tighten the plug to 17,6 N•m (13 ft-lb)

torque.

Remove the plug (Item 1) [Figure 20-120-16].

Installation: Tighten the plug (Item 1) [Figure 20-120-

16] to 17,6 N•m (13 ft-lb) torque.

270 of 1052 20-120-8 T870 Service Manual

BOB-TACH (POWER) BLOCK (CONT’D) Figure 20-120-21

Disassembly And Assembly (Cont'd)

Figure 20-120-19

2
3
1
2 P122209

1 Replace the O-ring (Item 1) and remove the orifice insert

P122207 (Item 2) [Figure 20-120-21]. Inspect and replace as
needed.

Remove the O-ring (Item 1), the spring (Item 2) and the Figure 20-120-22
check ball (Item 3) [Figure 20-120-19]. Inspect and
replace as needed.

Figure 20-120-20

1
P122210

Remove the relief valve (Item 1) [Figure 20-120-22].

P122208
Installation: Tighten the relief valve to 20 N•m (15 ft-lb)
torque.
Remove the plug (Item 1) [Figure 20-120-20].

Installation: Tighten the plug to 17,6 N•m (13 ft-lb)

torque.

271 of 1052 20-120-9 T870 Service Manual

BOB-TACH (POWER) BLOCK (CONT’D)

Disassembly And Assembly (Cont'd)

Figure 20-120-23

P122212

Replace the O-rings (Item 1) and the back-up rings (Item

2) [Figure 20-120-23].

Figure 20-120-24

P122213

Replace the O-ring (Item 1) [Figure 20-120-24].

NOTE: After repairing a machine that required the

power Bob-Tach valve electrical connectors
to be disconnected, inspect the loader to
make sure the Bob-Tach wedges function
correctly. If the wedges do not function per
the information in the Operation &
Maintenance Manual, the electrical
connectors will have to be switched between
the two Bob-Tach valve coils. Do a final
inspection to verify the wedges function
correctly.

272 of 1052 20-120-10 T870 Service Manual

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Removal And Installation

Description

The front auxiliary hydraulic coupler block is the

connection block that houses the two main auxiliary IMPORTANT
couplers along with a case drain coupler. These couplers
are for suppling hydraulic flow for various attachments. When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
The front auxiliary coupler block is located at the front of parts clean. Always use caps and plugs on hoses,
the left side lift arm. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Figure 20-130-1

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].

273 of 1052 20-130-1 T870 Service Manual

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-130-4
(CONT’D)

Disassembly And Assembly 1

2
Figure 20-130-2

2 1
1 2

2
1
2

1
P115529B

Remove the springs (Item 1) [Figure 20-130-4].

P-90002 Remove the O-rings (Item 2) [Figure 20-130-4] from the

fittings.

Remove the coupler fittings (Item 1) and the case drain Figure 20-130-5
coupler fitting (Item 2) [Figure 20-130-2].

Installation: Tighten the coupler fittings (Item 1) [Figure

20-130-2] to 110 N•m (81 ft-lb) torque.
1
Figure 20-130-3

P115533

3
Press center of the male coupler down and replace the
seal (Item 1) [Figure 20-130-5].

P-90003

Remove the female coupler (Item 1), case drain coupler

(Item 2) and male coupler (Item 3) [Figure 20-130-3].

Installation: Tighten the female and male coupler to 80

N•m (59 ft-lb) torque. Tighten the case drain coupler to
50 N•m (37 ft-lb) torque.

274 of 1052 20-130-2 T870 Service Manual

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-130-8
(CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-130-6

2 3

2
1 1

P115532

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

130-8] and replace coupler if damaged.
P115536
Assembly: Lightly lubricate the O-ring and seal with oil
before installation.
Remove the pintle (Item 1) from the case drain coupler
(Item 2) [Figure 20-130-6].

Inspect the pintle (Item 1), the case drain coupler (Item 2)
and the seal (Item 3) [Figure 20-130-6].

Replace the case drain coupler (Item 2) [Figure 20-130-

6] as an assemble if any part is damaged.

Figure 20-130-7

2
1

P115531

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

130-7] and replace coupler if damaged.

275 of 1052 20-130-3 T870 Service Manual

276 of 1052 20-130-4 T870 Service Manual
AUTOMATIC RIDE CONTROL

Description

The automatic ride control is an option that provides a

smoother ride, reduced load spillage, and improved
machine control when traveling over uneven ground with
heavy loads or in heavy digging applications.

277 of 1052 20-140-1 T870 Service Manual

AUTOMATIC RIDE CONTROL (CONT’D)

Removal And Installation

WARNING
Open the rear door.
AVOID INJURY OR DEATH
Remove the rear grille and engine cover. (See Removing
Always clean up spilled fuel or oil. Keep heat, flames,
on Page 50-60-1.)
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.

WARNING W-2103-0508

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 WARNING
support device can allow the lift arms or attachment
to fall and cause injury or death. RIDE CONTROL ACCUMULATOR INSTALLED
W-2059-0598
PRESSURIZED FLUID CAN CAUSE SERIOUS INJURY
After fully lowering the lift arms or installing an
approved lift arm support device, use lift arm bypass
control for 5 seconds to release pressure from lift
DANGER circuit before servicing.
See Operation & Maintenance Manual or Service
Manual for lift arm bypass control instructions.
W-3015-0816

Drain the hydraulic fluid reservoir. (See Removing And

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

Figure 20-140-1
P-90328

AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure 3
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
2

IMPORTANT P121154

When repairing hydrostatic and hydraulic systems, Disconnect the harness (Item 1) [Figure 20-140-1] from
clean the work area before disassembly and keep all the bottom of the filter.
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly Remove the two bolts (Item 2) and reposition the fuel
damage the system. filter assembly (Item 3) [Figure 20-140-1].
I-2003-0888

278 of 1052 20-140-2 T870 Service Manual

AUTOMATIC RIDE CONTROL (CONT’D) Figure 20-140-4

Removal And Installation (Cont’d)

Figure 20-140-2 1

P115821

Reposition the clamp (Item 1) and remove the fuel fill

P122353
hose (Item 2) [Figure 20-140-4] from the tank.

Cover the fuel tank inlet.

Remove the two bolts (Item 1) [Figure 20-140-2].
Figure 20-140-5
Figure 20-140-3

P128342
P122355

Disconnect the three connectors (Item 1) [Figure 20-

Remove the hose (Item 1) [Figure 20-140-3]. 140-5] from the manifold.

279 of 1052 20-140-3 T870 Service Manual

AUTOMATIC RIDE CONTROL (CONT’D) Figure 20-140-8

Removal And Installation (Cont’d)

2
Figure 20-140-6

1
1

P128529

Remove the two nuts (Item 1) and the accumulator /

P128096 manifold assembly (Item 2) [Figure 20-140-8].

Remove the hose (Item 1) [Figure 20-140-6].

Figure 20-140-7

P128530

Remove the two hoses (Item 1) [Figure 20-140-7] from

the manifold.

280 of 1052 20-140-4 T870 Service Manual

AUTOMATIC RIDE CONTROL (CONT’D)

Checking The Pressure In The Accumulator

The nitrogen charge in the accumulator will decrease

IMPORTANT
over time. This will result in decreased effectiveness of
the automatic ride control benefits. When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
NOTE: The signs of a low accumulator charge parts clean. Always use caps and plugs on hoses,
include: excessive lift arm movement, tubelines and ports to keep dirt out. Dirt can quickly
reduced ride control performance, or loss of damage the system.
I-2003-0888
ride control function.

Remove the automatic ride control assembly. (See

Removal And Installation on Page 20-140-2.)

The tools listed will be needed to do the following WARNING

procedure:
AVOID INJURY OR DEATH
Hydac Adapter Tool Kit Bobcat P/N 7311020. 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.
WARNING W-2103-0508

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 WARNING
to fall and cause injury or death.
W-2059-0598 RIDE CONTROL ACCUMULATOR INSTALLED
PRESSURIZED FLUID CAN CAUSE SERIOUS INJURY
After fully lowering the lift arms or installing an
approved lift arm support device, use lift arm bypass
DANGER control for 5 seconds to release pressure from lift
circuit before servicing.
See Operation & Maintenance Manual or Service
Manual for lift arm bypass control instructions.
W-3015-0816

Figure 20-140-9

P-90328

AVOID DEATH
• Disconnecting or loosening any hydraulic 1
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

P128321

Remove the cap (Item 1) [Figure 20-140-9] from the

accumulator.

281 of 1052 20-140-5 T870 Service Manual

AUTOMATIC RIDE CONTROL (CONT’D) Figure 20-140-12

Checking The Pressure In The Accumulator (Cont’d)

Figure 20-140-10 1

2
1

P128489

Turn the T-handle (Item 1) [Figure 20-140-12] counter

P128322 clockwise until the gauge begins to move (DO NOT
TURN THE T-HANDLE MORE THAN THREE TIMES).

Loosen the Allen screw (Item 1) [Figure 20-140-10] Pressure in the accumulator should be 1189 psi [82 bar].
approximately 1/4 turn.
Close the valve by turning the T-handle (Item 1) [Figure
Figure 20-140-11 20-140-12] clockwise.

Release any pressure by opening the manual bleed valve

(Item 2) [Figure 20-140-12].

Remove the tool / gauge from the accumulator.

2
Tighten the Allen screw (Item 1) [Figure 20-140-10] to 20
N•m (15 ft-lb) torque.

1
P128488

Make sure the manual bleed valve (Item 1) is closed.

Install the tool / gauge (Item 2) [Figure 20-140-11] onto
the accumulator.

282 of 1052 20-140-6 T870 Service Manual

AUTOMATIC RIDE CONTROL (CONT’D) Figure 20-140-14

Adding Nitrogen To The Accumulator

Remove the automatic ride control assembly. (See

Removal And Installation on Page 20-140-2.)

The tools listed will be needed to do the following

procedure:
1
Hydac Adapter Tool Kit Bobcat P/N 7311020.

WARNING
P128322

Wear safety glasses to prevent eye injury when any

of the following conditions exist: Loosen the Allen screw (Item 1) [Figure 20-140-14]
• Pressurized fluids and springs or other stored approximately 1/4 turn.
energy components.
• Flying debris or loose material is present. Figure 20-140-15
• Engine is running.
• Tools are being used.
W-2505-0604

WARNING
RIDE CONTROL ACCUMULATOR INSTALLED
PRESSURIZED FLUID CAN CAUSE SERIOUS INJURY
After fully lowering the lift arms or installing an
approved lift arm support device, use lift arm bypass
control for 5 seconds to release pressure from lift
2
circuit before servicing. P128488
See Operation & Maintenance Manual or Service
Manual for lift arm bypass control instructions.
W-3015-0816
Install the tool / gauge (Item 1) [Figure 20-140-15] onto
the accumulator.

Figure 20-140-13 Make sure the manual bleed valve (Item 2) [Figure 20-
140-15] is closed.

P128321

Remove the cap (Item 1) [Figure 20-140-13] from the

accumulator.

283 of 1052 20-140-7 T870 Service Manual

AUTOMATIC RIDE CONTROL (CONT’D) Figure 20-140-18

Adding Nitrogen To The Accumulator (Cont’d)

1
Figure 20-140-16

2
1

P128491

Turn the T-handle (Item 1) [Figure 20-140-18] counter

P128490 clockwise until the gauge begins to move (DO NOT
TURN THE T-HANDLE MORE THAN THREE TIMES).

Install the hose (Item 1) [Figure 20-140-16] to the tool on Pressure in the accumulator should be 1189 psi [82 bar].
the accumulator.
Slowly open the valve on the nitrogen tank. Close the
Figure 20-140-17 valve by turning the T-handle (Item 1) [Figure 20-140-18]
until the accumulator pressure is correct. Close the valve
on the nitrogen tank.
1 Close the valve by turning the T-handle (Item 1) [Figure
20-140-18] clockwise.

Release any pressure by opening the manual bleed valve

(Item 2) [Figure 20-140-18].

Remove the hose from the tank and the accumulator.

Tighten the Allen screw (Item 1) [Figure 20-140-14] to 20

N•m (15 ft-lb) torque.

P128327

Install the other end of the hose / fitting (Item 1) [Figure

20-140-17] to the nitrogen tank.

284 of 1052 20-140-8 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

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 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-6
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-7
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-21
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-31
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-34

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
Tensioner Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-4

TWO-SPEED / BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Valve Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-2
Valve Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-4

285 of 1052 30-01 T870 Service Manual

DRAIN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
Drain Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1

286 of 1052 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.

287 of 1052 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 ENGINE CONTROL UNIT (ECU) 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

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.

288 of 1052 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 hydrostatic motor is at the bottom.
pump. 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
NOTE: One speed motor option is no longer available
on later model machines.

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 7024981). (See Capacities on Page
SPEC-10-5.)

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.

289 of 1052 30-20-1 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (CONT’D) Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Removal And Installation
Remove the track. (See Track Removal And Installation
on Page 40-20-6.)

IMPORTANT Figure 30-20-2

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 1

Place the loader on jackstands. (See Procedure on Page

10-10-1.)

DANGER P100811

Remove the mounting bolts (Item 1) [Figure 30-20-2]

from the access cover and remove the cover from the
loader.

Remove the sprocket. (See Sprocket Removal And

Installation (Single Speed) on Page 40-20-15.)

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

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

290 of 1052 30-20-2 T870 Service Manual

HYDROSTATIC DRIVE 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 hydrostatic 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 258
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.

291 of 1052 30-20-3 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (CONT’D)

Parts Identification

10

9
8
7
6
5

4 25
3 24
2 12
23
22
21
11
10
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
36 37
60
44
43 59
45 55
58
57

56
62
MS2290S

292 of 1052 30-20-4 T870 Service Manual

HYDROSTATIC DRIVE 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
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

293 of 1052 30-20-5 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (CONT’D) Figure 30-20-8

Disassembly And Assembly

Figure 30-20-6

1
2

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 (Item 1), brake and motor installation.
housings for proper alignment during
assembly [Figure 30-20-6]. Assembly: Apply 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 2)

[Figure 30-20-6], these serial numbers may be needed
when ordering replacement parts.

Figure 30-20-7

2
1

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).

294 of 1052 30-20-6 T870 Service Manual

HYDROSTATIC DRIVE 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
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.

295 of 1052 30-20-7 T870 Service Manual

HYDROSTATIC DRIVE 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.
Assembly: Extra outer discs 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.

296 of 1052 30-20-8 T870 Service Manual

HYDROSTATIC DRIVE 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
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 30-20-16].
The dimensional measurement must be 8,7 ± 0,1 mm
(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.

297 of 1052 30-20-9 T870 Service Manual

HYDROSTATIC DRIVE 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.
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 rings (Item 1) [Figure

P-48685 30-20-22] under the seals, from the rear housing.

Assembly: Apply a slight amount of oil to the O-rings

Remove the rear housing assembly (Item 1) [Figure 30- and seals (Item 1) [Figure 30-20-22].
20-20] from the rotating group / front housing assembly.
Remove and inspect the stop pin (Item 2) [Figure 30-20-
22].

298 of 1052 30-20-10 T870 Service Manual

HYDROSTATIC DRIVE 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].

Remove and replace the two seals and back-up 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.

299 of 1052 30-20-11 T870 Service Manual

HYDROSTATIC DRIVE 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
Replace the O-ring (Item 2) [Figure 30-20-29].

Remove the plug (Item 1) [Figure 30-20-27]. Assembly: Apply Loctite® activator 7649 to the plug
threads. Allow ten seconds for the activator to dry. Apply
Figure 30-20-28 Loctite® 243 to the plug threads. Install the plug (Item 1)
[Figure 30-20-29] and tighten to 60 N•m (44 ft-lb) torque.

Figure 30-20-30
1

N-18311

Replace the O-ring on the plug (Item 1) [Figure 30-20-

N-18313
28].

Assembly: Apply Loctite® activator 7649 to the plug Remove the plug (Item 1) [Figure 30-20-30].
threads. Allow ten seconds for the activator to dry. Apply
Loctite® 243 to the plug threads. Install the plug (Item 1)
[Figure 30-20-28] and tighten to 85 N•m (63 ft-lb) torque.

300 of 1052 30-20-12 T870 Service Manual

HYDROSTATIC DRIVE 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].
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.

301 of 1052 30-20-13 T870 Service Manual

HYDROSTATIC DRIVE 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

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.

302 of 1052 30-20-14 T870 Service Manual

HYDROSTATIC DRIVE 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
bearing and face seal area. NOTE: The 40 kN (9000 lbf) is NOT the amount of
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].

303 of 1052 30-20-15 T870 Service Manual

HYDROSTATIC DRIVE 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
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.

304 of 1052 30-20-16 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (CONT’D) Figure 30-20-48

Disassembly And Assembly (Cont'd)

Figure 30-20-46
1

P100802A

Rotate the hydrostatic drive motor so that the drain plug

P0122 (Item 1) [Figure 30-20-48] 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 7024981).
Remove and inspect the bearing (Item 1) [Figure 30-20-
46] located in the front housing. Clean the threads of the plug and drain hole. Apply
Loctite® 243 to the plug threads. Install and tighten the
Replace the bearing if worn or damaged. plug.

Figure 30-20-47

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.

305 of 1052 30-20-17 T870 Service Manual

306 of 1052 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 hydrostatic motor is at the bottom.
pump. 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

P100737A

Rotate the hydrostatic drive motor so that the plug (Item

1) [Figure 30-21-1] is at the top. Add high performance
synthetic oil (P/N 7024981). (See Capacities on Page
SPEC-10-5.)

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.

307 of 1052 30-21-1 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Raise the lift arms and install an approved lift arm
(CONT’D) support device. (See Installing on Page 10-20-2.)

Removal And Installation Remove the track. (See Track Removal And Installation
on Page 40-20-6.)

Figure 30-21-2
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
damage the system. 1
I-2003-0888

Place the loader on jackstands. (See Procedure on Page

10-10-1.)

DANGER
P100811

Remove the mounting bolts (Item 1) [Figure 30-21-2]

from the access cover and remove the cover from the
loader.

Remove the sprocket. (See Sprocket Removal And

Installation (Two-Speed) on Page 40-20-15.)

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

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

308 of 1052 30-21-2 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-4
(CONT’D)

Removal And Installation (Cont'd)

Figure 30-21-3 2 3

5 4 1
3

P100901
1 2
Installation: Install both flanges and tighten the bolts to
half of the required torque in the sequence shown in
4 [Figure 30-21-4]. Retighten all bolts to required torque in
P109063 the same sequence.

Disconnect the hydraulic hose (Item 1) [Figure 30-21-3] Figure 30-21-5

that goes to the two-speed port on the two-speed / brake
block.

Disconnect the hydraulic hose (Item 2) [Figure 30-21-3] 1 1

that goes to the drain manifold.

Disconnect the hydraulic hose (Item 3) [Figure 30-21-3]

that goes to the two-speed port on the two-speed / brake
block.

Remove the eight flange bolts (Item 4) from the main

drive hoses. Remove the flanges and drive hoses (Item
5) [Figure 30-21-3].

Installation: Fill the main drive hose ports on the motor P-85991
with new hydraulic oil before installing the drive hoses.
With an arm hoist support the hydrostatic motor.

Remove the ten hydrostatic motor mounting bolts (Item

1) [Figure 30-21-5].

Installation: Tighten the motor mounting bolts to 258

N•m (190 ft-lb) torque.

Remove the hydrostatic motor from the loader.

309 of 1052 30-21-3 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (CONT’D)

Parts Identification

10

9
8
65 7

6
5

4
3
12
2 23

11 22
65
21
10

1 20

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
26 31
28 45
27 46
47
48
49 50
51 63
52
53 62
61
55 54 60
59
58
57 NA2870s
56

310 of 1052 30-21-4 T870 Service Manual

HYDROSTATIC DRIVE 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
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

311 of 1052 30-21-5 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Assembly: Replace the gasket and torque bolts to 35 -
(CONT’D) 39 N•m (26 - 29 ft-lb).

Disassembly And Assembly Figure 30-21-8

Figure 30-21-6

N-18296

P100869
Remove the disc spring (Item 1) [Figure 30-21-8] from
the brake housing.
NOTE: Mark the motor, brake and motor housings for
proper alignment during assembly [Figure 30- NOTE: Mark the top side of the disc spring for proper
21-6]. installation.

Drain the oil from the motor casing. Assembly: Put multi-purpose moly grease on the
surface of the disc spring where it contacts the piston.
Inspect for the vendor motor serial number (Item 1)
[Figure 30-21-6], these serial numbers may be needed
when ordering replacement parts.

Figure 30-21-7

P100799

Remove the mounting bolts (Item 1) and the brake cover

plate (Item 2) [Figure 30-21-7].

NOTE: Remove every other bolt, then uniformly

remove the last twelve bolts to maintain equal
preload on the brake cover plate.

312 of 1052 30-21-6 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-11
(CONT’D)

Disassembly And Assembly (Cont'd)

Figure 30-21-9

1
2

P100868

1 Inspect the piston surface (Item 1) and the bushing

surface (Item 2) [Figure 30-21-11] in the brake shaft.
P100804
NOTE: The bushing (Item 2) [Figure 30-21-11] can be
replaced in the brake shaft. When the bushing
Remove the piston from the brake housing [Figure 30- is replaced, install the bushing flush with the
21-9]. top of the brake shaft.

NOTE: The use of air pressure through the brake line

connection (Item 1) [Figure 30-21-9] will aid in
piston removal.

Figure 30-21-10

2
P100801

Inspect the brake piston (Item 1) [Figure 30-21-10] for

damage including the surface that contacts the brake
shaft.

Replace the seal (Item 2) [Figure 30-21-10].

Assembly: Apply oil to the seal (Item 2) [Figure 30-21-

10] for added protection when installing the brake piston.

313 of 1052 30-21-7 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-13
(CONT’D)

Disassembly And Assembly (Cont'd)

Figure 30-21-12

N-18347
3
2
Assembly: Clamp the disc pack in a vise and inspect the
disc pack height [Figure 30-21-13].
1 P100866
Assembly: The correct disc pack reference
specifications is 37,7 mm (1.48 in).
Remove the five mounting bolts (Item 1) [Figure 30-21-
12] and washers from the brake housing. Assembly: Extra outer discs are used to reduce the
number of required shims [Figure 30-21-13] to make up
Remove the brake housing (Item 2) [Figure 30-21-12] the required thickness for the brake pack.
from the rear housing.
NOTE: Brake pack height is for reference only.
Remove the snap ring and inner piston seal (Item 3)
[Figure 30-21-12]. Figure 30-21-14

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.

Assembly: Install new washers on the brake housing 1

mount bolts (Item 1) [Figure 30-21-12].

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.
P100867
Assembly: Tighten bolts to 117 - 122 N•m (86 - 90 ft-lb)
torque.
Assembly: Install the needed amount of shims (Item 1)
[Figure 30-21-14]. Outer discs can also be used as
shims.

314 of 1052 30-21-8 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-17
(CONT’D)

Disassembly And Assembly (Cont'd)

Figure 30-21-15
1

2
3

P100858

1 Disassembly: Remove the brake discs (Item 1) [Figure

30-21-17] and shims from the brake shaft.
P100805

Figure 30-21-18
Assembly: Assemble the brake discs into a pack making
sure the inner discs (Item 1), alternate with the outer disc
(Item 2) and an outer disc is placed at each end of the
disc pack with the shims (Item 3) [Figure 30-21-15] and
the base of the pack.
1
Figure 30-21-16
2

2
P100859

Remove the brake shaft (Item 1) [Figure 30-21-18] 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 30-21-18]
[Figure 30-21-12] and brake piston outer seal (Item 2) on the rear housing.
[Figure 30-21-10]. 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 30-21-16].
The dimensional measurement must be 8,7 ± 0,1 mm
(0.343 ± 0.003 in), 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.

315 of 1052 30-21-9 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-21
(CONT’D)

Disassembly And Assembly (Cont'd)

Figure 30-21-19

P100872

Remove the plug (Item 1) [Figure 30-21-21] from the

rear housing.
P100870
Figure 30-21-22

Remove the two-speed spool assembly (Item 1) [Figure

30-21-19] from the rear housing.

Figure 30-21-20

1 2

P100871
2
4
3 Remove the spool (Item 1) [Figure 30-21-22].

N-22501 Assembly: Install new O-ring (Item 2) [Figure 30-21-22]

on the plug and torque to 50 N•m (37 ft-lb).

Inspect the two-speed spool (Item 1), the spring (Item 2),
washer (Item 3) and the snap ring (Item 4) and replace as
needed [Figure 30-21-20].

NOTE: If the two-speed spool (Item 1) [Figure 30-21-

20] is damaged the entire rear housing
assembly has to be replaced.

The two-speed spool (Item 1) [Figure 30-21-

20] has an internal make-up spool, which is
not serviceable. The spool will be damaged if
disassembled.

316 of 1052 30-21-10 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Assembly: Clean the threads on the bolts and front
(CONT’D) housing assembly. Apply Loctite® #243 and tighten the
ten bolts (Item 1) [Figure 30-21-24] to 210 - 220 N•m
Disassembly And Assembly (Cont'd) (154 - 162 ft-lb) torque. Clean the threads on the two (8
mm) bolts (Item 2) [Figure 30-21-24] and the cam ring.
Figure 30-21-23 Apply Loctite® #243 and tighten the bolts to 70 - 77 N•m
(52 - 57 ft-lb).

1 Figure 30-21-25
2 4 3
LATER
MODELS
1
1 1

2 2

N-22504
1

Remove the spring (Item 1), washer (Item 2) and rear

P100861A
spring (Item 3) from the spool (Item 4) [Figure 30-21-23].

Inspect all parts and replace as needed. Remove the eight mounting bolts (Item 1) [Figure 30-21-
25] from the rear housing.

Remove the two cam ring mount bolts (Item 2) [Figure

Figure 30-21-24 30-21-25].
EARLIER
MODELS Turn the housing, cam ring, and rotating group assembly
over and place on a stand.
1
1 1
Assembly: Clean the threads on the bolts and front
housing assembly. Apply Loctite® #243 and tighten the
ten bolts (Item 1) [Figure 30-21-25] to 210 - 220 N•m
(154 - 162 ft-lb) torque. Clean the threads on the two cam
1 ring mounting bolts (Item 2) [Figure 30-21-25] and the
1
cam ring. Apply Loctite® #243 and tighten the bolts to
282 - 300 N•m (208 - 221 ft-lb).
1
2 2

P100861

Remove the ten mounting bolts (Item 1) [Figure 30-21-

24] from the rear housing.

Remove the two (8 mm) cam ring mount bolts (Item 2)

[Figure 30-21-24].

Turn the housing, cam ring, and rotating group assembly

over and place on a stand.

317 of 1052 30-21-11 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-28
(CONT’D)

Disassembly And Assembly (Cont'd)

Figure 30-21-26
1

P100856

Remove the springs from the distributor (Item 1) [Figure

30-21-28].
P100860
Inspect the distributor surfaces for scratches.

Remove and replace with a new O-ring (Item 1) [Figure Assembly: Apply a small amount of grease to the
30-21-26]. springs to hold them in place during installation.

Remove the distributor (Item 2) [Figure 30-21-26] from Figure 30-21-29

the rear housing.

Assembly: Install the distributor (Item 2) [Figure 30-21-

26] by using the alignment pin.

Figure 30-21-27

2 1

P100855

Remove the six seals (Item 1), and six back-up rings
(Item 2) [Figure 30-21-29] from the distributor.
2

N-18318

Remove the seal and back-up ring (Item 1) [Figure 30-

21-27] under the seal, from the rear housing.

Assembly: Apply a slight amount of oil to the O-rings

and seals (Item 1) [Figure 30-21-27].

Remove and inspect the stop pin (Item 2) [Figure 30-21-

27].

318 of 1052 30-21-12 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-32
(CONT’D)

Disassembly And Assembly (Cont'd)

Figure 30-21-30

P100873
1

Inspect the O-ring (Item 1) [Figure 30-21-32] on the plug

and replace as needed. Torque to 60 N•m (44 ft-lb)
P100812
Figure 30-21-33

Assembly: When installing the distributor align the stop

pin (Item 1) with the notch in the distributor (Item 2)
[Figure 30-21-30].

When the distributor is aligned correctly, the distributor

1
can be depressed slightly by hand and will return to its
original position.

Figure 30-21-31

1
P100875

Remove the plug (Item 1) [Figure 30-21-33].

P100874

Remove the drain plug (Item 1) [Figure 30-21-31].

319 of 1052 30-21-13 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-36
(CONT’D)

Disassembly And Assembly (Cont'd) 2

1
Figure 30-21-34

4
1
3
2

P100924

Remove and replace the O-ring (Item 1) [Figure 30-21-

36] from the front housing assembly.
N-18314
Assembly: Slightly smear the O-ring (Item 1) [Figure
30-21-36] with grease to hold in place.
Remove the spring (Item 1) shim (Item 2) and poppet
(Item 3) [Figure 30-21-34]. Remove the rotating group (Item 2) [Figure 30-21-36]
from the front housing assembly.
Inspect all parts and replace as needed.
Figure 30-21-37
Install a new O-ring (Item 4) [Figure 30-21-34] on the
plug and replace as needed. Torque to 25 N•m (18 ft-lb)

Figure 30-21-35

2
1

1
P-48690

Remove the snap ring (Item 1) [Figure 30-21-37] from

P100925 the bottom side of the rotating group.

Remove the cam ring (Item 1) [Figure 30-21-35] from the

front housing assembly.

Inspect the cam ring inside surface for wear and

scratches.

Assembly: Align the marks (Item 2) [Figure 30-21-35]

on the cam rings to the front housing.

320 of 1052 30-21-14 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-40
(CONT’D)

Disassembly And Assembly (Cont'd)

Figure 30-21-38

P100927

The retainer ring (Item 1) [Figure 30-21-40] cannot be

1
removed from the top side of the rotating group, because
P-48691 the rpm target disc is attached directly to the rotating
group.

Remove the retainer ring (Item 1) [Figure 30-21-38] from Figure 30-21-41
the bottom side of the rotating group.

Figure 30-21-39

2
1
P100928

P100926 Lift the retaining ring (Item 1) [Figure 30-21-41].

Use low air pressure and remove the roller / piston

Remove the snap ring (Item 1) [Figure 30-21-39] from assembly (Item 2) [Figure 30-21-41] from the cylinder
the top side of the rotating group. block.

NOTE: Soak the roller / piston assembles (Item 2)

[Figure 30-21-41] in oil and put all roller /
piston assembles back in the original bore.

NOTE: The roller / piston assembly (Item 2) [Figure

30-21-41] is not a serviceable part.

321 of 1052 30-21-15 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-44
(CONT’D)

Disassembly And Assembly (Cont'd) 1

2
Figure 30-21-42

1
P100932

Assembly: Install the front housing (Item 1) and bearing

over the shaft. Install the special tool (MEL1562) (Item 2)
P100929 [Figure 30-21-44] over the bearing and press the
bearing onto the shaft. Apply 40 kN (9000 lbf) to set the
bearing. Rotate the housing to inspect for free travel.
Disassembly: Remove the oil fill plug (Item 1) [Figure
30-21-42] from the housing to drain the oil from the NOTE: The 40 kN (9000 lbf) is NOT the amount of
bearing and face seal area. pressure required by the press. It is the
amount of downward force applied by the
Clean the threads of the plug and drain hole. Apply press.
Loctite® 243 to the plug threads. Install and tighten the
Assembly: Install the split ring (Item 3) [Figure 30-21-
plug.
44] with a feeler gauge measure the distance between
the split ring and the top of the bearing inner race.
Figure 30-21-43
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

remove the tool.
1

P100931

Disassembly: With a hammer and punch remove the

split ring and the preload washer located under the split
ring (Item 1) [Figure 30-21-43].

322 of 1052 30-21-16 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-47
(CONT’D)

Disassembly And Assembly (Cont'd)

Figure 30-21-45
2

1
2

P13083

Assembly: Remove and replace the face seal (Item 1)

[Figure 30-21-47] from the shaft.
P100934
Assembly: Install a new bearing (Item 2) [Figure 30-21-
47] onto the shaft.
Disassembly: Install the bearing puller (Item 1) [Figure
30-21-45] under the front housing and support the puller Figure 30-21-48
and housing with blocks.

Disassembly: Press the shaft (Item 2) [Figure 30-21-45] 1

from the housing.

Figure 30-21-46

P100941

Remove and inspect the bearing (Item 1) [Figure 30-21-

48] 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 30-21-46].

NOTE: The bearing will not be serviceable during the

removal procedure. Be sure to have a new
bearing on hand before removing the old
bearing.

323 of 1052 30-21-17 T870 Service Manual

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-50
(CONT’D)

Disassembly And Assembly (Cont'd)

Figure 30-21-49 2 1

2
1

P100940

Remove the shaft seal (Item 1) [Figure 30-21-50].

P100939 Remove the bearing cup (Item 2) [Figure 30-21-50] if it

needs replacement.

Remove and replace the face seal (Item 1) [Figure 30- Figure 30-21-51
21-49] on the front housing.

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

30-21-49] 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 30-21-51] 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 7024981).

Clean the threads of the plug and drain hole. Apply

Loctite® 243 to the plug threads. Install and tighten the
plug.

324 of 1052 30-21-18 T870 Service Manual

CHARGE PRESSURE Testing

Description

Charge pressure is a supply of oil to the hydrostatic

pumps. Charge pressure is regulated by a charge relief
WARNING
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed When the engine is running during service, the
from the drive circuit, pump and motor “internal leakage” driving and steering controls must be in neutral and
and from the hydrostatic motors shuttle (flushing) valve. the parking brake engaged. Failure to do so can
cause injury or death.
Charge pressure is also used to operate other hydraulic W-2006-1209
functions, such as shifting the auxiliary spool, and to pilot
open the BICS™ system for the lift and tilt in the main The tools listed will be needed to do the following
hydraulic control valve. procedure:

The charge pressure sender is located on the hydraulic MEL1355-2 - Pressure gauge 6,9 MPa (68,9 bar) (1000
fan motor. Charge pressure alarm settings are pre- psi)
programmed into the main controller and are based on MEL1723 - Female Test Coupler
loader type and options installed. 7246786 - Female Test Coupler
Hydraulic hose - Must be rated for pressures above 6,9
MPa (68,9 bar) (1000 psi).

Figure 30-30-1

1 3

2
4

P121789

Test ports have changed on the Main valve. If your test

port looks like (Item 2) use test coupler (Item 1). If your
test port looks like (Item 4), use test coupler (Item 3)
[Figure 30-30-1].

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

325 of 1052 30-30-1 T870 Service Manual

CHARGE PRESSURE (CONT’D) Figure 30-30-3

Testing (Cont’d)

Figure 30-30-2

1
1

3
3 P109149B
2

Figure 30-30-4
P-43196D

Assemble the gauge (Item 1), hose (Item 2) and the

correct test coupler (Item 3) [Figure 30-30-2]. Tighten all
fittings.

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
P107933
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Connect the test coupler (Item 1) [Figure 30-30-4] to the
test port (Item 1) [Figure 30-30-3].
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.) Connect the Remote Start Tool. (See REMOTE START
TOOL KIT - MEL1563 on Page 10-60-1.) or (See
Raise the operator cab. (See Raising on Page 10-30-1.) REMOTE START TOOL (SERVICE TOOL) KIT -
7217666 on Page 10-61-1.)

Start the loader and warm the hydraulic fluid to 60°C

(140°F).

Charge pressure at high idle, with the fluid temperature of

60°C (140°F) is 2861,3 - 3550,8 kPa (28,6 - 35,5 bar)
(415 - 515 psi) with the pump in neutral.

326 of 1052 30-30-2 T870 Service Manual

CHARGE PRESSURE (CONT’D)

Sender Removal And Installation

Remove the lower fan duct. (See Lower Fan Duct

Removal And Installation on Page 70-60-4.)

Figure 30-30-5

P115778A

Disconnect the wire (Item 1) [Figure 30-30-5] from the

sender.

Remove the sender (Item 2) [Figure 30-30-5] from the

motor.

Installation: Tighten the charge pressure sender to 10 -

10,9 N•m (7.4 - 8.1 ft-lb) torque.

NOTE: Replace the O-ring on the sender before

installation.

327 of 1052 30-30-3 T870 Service Manual

CHARGE PRESSURE (CONT’D) Figure 30-30-7

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 30-30-6

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)

1 [Figure 30-30-7] used to adjust the charge pressure.

NOTE: 1,0 mm shim (Item 1) [Figure 30-30-7] = 299,9

kPa (3,0 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 2964,7 - 3654,2

kPa (29,6 - 36,5 bar) (430 - 530 psi).

If the charge pressure is not correct remove the charge

relief valve (Item 1) [Figure 30-30-6].

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.

328 of 1052 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 hydrostatic pump is a fully proportional dual piston forward or reverse drive motor rotation is obtained.
pump in one pump casing. The end caps are removable
to gain access to the rotating assemblies. There are swash plate angle sensors on the bottom of
the pump that monitor swash plate movement.
The hydraulic controllers are supplied with charge
pressure from an external charge pump. 12 volt electrical Ports are labeled on the hydrostatic pump casting.
solenoids shift a spool in the hydraulic controller that
directs flow to a servo piston.

Figure 30-40-1

X1 X 2 X1
X2
R

MB MB

RIGHT PUMP LEFT PUMP

B B T NA9302
A M A M G MA A

A,B Service Line Ports (High Pressure Outlet Ports to Drive Motors)
T1 Case Drain Port
MA Operating Pressure of “A” Port
MB Operating Pressure of “B” Port
R Air Bleed Port
X1,X2 Control Pressure Gauge Port
G Charge Pressure Inlet Port
MG Gauge Port For Charge Pressure

329 of 1052 30-40-1 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-2

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
removed when the hydrostatic pump is separated from
the engine / hydrostatic pump cast mount. 1

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.

Raise the lift arms and install an approved lift arm P-90226A
support device. (See Installing on Page 10-20-2.)

Locate the two hydraulic controllers (Item 1) [Figure 30-

40-2] on the hydrostatic pumps.
WARNING Figure 30-40-3

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. 1
W-2059-0598

Place the loader on jackstands. (See Procedure on Page

10-10-1.)

WARNING 1
P-90239

Put jackstands under the front axles and rear corners

of the frame before running the engine for service. Disconnect the wire harness (Item 1) [Figure 30-40-3]
Failure to use jackstands can allow the machine to from both sides of the hydrostatic pump.
fall or move and cause injury or death.
W-2017-0286

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

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

330 of 1052 30-40-2 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-6

Hydraulic Controller Removal And Installation

(Cont'd)

Figure 30-40-4

2 2

1
1

P-90209

Install the controller with the feedback lever (Item 4)

[Figure 30-40-5] in the center of the servo piston groove
P-90208A (Item 1) [Figure 30-40-6].

NOTE: Do NOT remove the three screens (Item 2)

Remove the four bolts (Item 1) [Figure 30-40-4] from the [Figure 30-40-6] they will be damaged during
hydraulic controller. removal and must be replaced.

Installation: Tighten the bolts to 10,4 N•m (7.7 ft-lb). When a hydraulic controller is replaced, the
hydrostatic pumps must be calibrated. (See
Figure 30-40-5 Hydraulic Controller Neutral Adjustment on
Page 30-40-34.)
3
2

1
4

P-90210

Remove the cover (Item 1) gaskets (Item 2) and control

(Item 3) [Figure 30-40-5] from the pump.

331 of 1052 30-40-3 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-8

Removal And Installation

Remove the hydrostatic pump / engine assembly from

the loader. (See Engine Removal And Installation on
Page 70-10-15.)

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 30-40-8] 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.
I-2003-0888 Remove the nut and washer from the pump drive shaft.

Figure 30-40-7 Remove the pump pulley from the pump drive shaft.

Figure 30-40-9

1
1
P-90221

P-90223
Loosen the nut (Item 1) [Figure 30-40-7] on the
hydrostatic pump drive shaft.
Remove the two bolts and nuts (Item 1) [Figure 30-40-9].
Installation: Tighten the nut to 257 - 325 N•m (190 - 240
ft-lb) torque. Installation: Tighten the bolts and nuts to 88 - 95 N•m
(65 - 70 ft-lb) torque.

Remove the hydrostatic pump from the mounting bracket

and drive belt housing.

BEFORE STARTUP: Fill the hydrostatic pump with

hydraulic oil. This will remove trapped air in the
hydrostatic pumps before startup. (See Hydrostatic Pump
Startup on Page 30-40-5.)

332 of 1052 30-40-4 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D)

Hydrostatic Pump Startup

Before putting a hydrostatic pump back into operation,

the hydrostatic pump must 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 will cause premature

wear or permanent pump damage.

Under normal operation, the charge pump will keep the

hydrostatic pumps filled.

Fill the hydrostatic pump 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.
Fill the hydrostatic pump case as much as possible
before startup.

Figure 30-40-10

P-90226A

Remove the air bleed plugs (Item 1) [Figure 30-40-10].

BEFORE STARTUP: 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 startup.

Installation: Tighten plugs to 25 N•m (18 ft-lb) torque.

NOTE: The hydrostatic pump is removed from the

loader for photo clarity.

333 of 1052 30-40-5 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D)

Parts Identification

3 1
4 1
1. O-ring
2. Bolt 5
3. End Housing 6
4. Right Rotating Assembly 7
5. Timing Pin
6. Bearing
7. Spacer/Coupler
8. Positioning Wire
9. Positioning Pin
10. Position Sensor 8
9 2
11. Washer
1 10

12
2 16
14
16 2
15

13

13
16

17

14 20
19
18 5
22
23

12. Steel Cover

13. Hydraulic Controller
2 6 14. High Pressure Relief
15. Case Housing
16. Plug
21 17. Dowel Pin
8 18. Charge Pressure Relief
9 1 19. Left Servo
1 20. Right Servo
21. Left Rotating Assembly
10 22. End Housing
2 23. Key

12
2
NA8538S

334 of 1052 30-40-6 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-13

High Pressure Relief And Bypass Valve

Figure 30-40-11

1
1

P-64437

Inspect the valve seat surface (Item 1) [Figure 30-40-13]

P-64431 for scratches and replace as needed.

Inspect the spring (Item 2) [Figure 30-40-13] for

There are four system high pressure relief valves (Item 1) breakage.
[Figure 30-40-11] in the back of the hydrostatic pump.
Inspect the seats inside the case housing.
Remove the relief valve caps (Item 1) [Figure 30-40-11].
Do not disassemble the relief valve assembly. If
Installation: Tighten caps to 150 - 170 N•m (111 - 125 ft- replacement is required, replace as an assembly.
lb) torque.
Factory setting on the relief valve is 39500 kPa (395 bar)
Figure 30-40-12 (5729 psi).

4
3

2 1

P-64436

Replace the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-40-12].

Remove relief valve assembly (Item 3) [Figure 30-40-12]

from the valve cap.

Inspect the conical spring (Item 4) [Figure 30-40-12] for

damage.

335 of 1052 30-40-7 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-15

Charge Relief Valve

1 4 5
Figure 30-40-14 6
2 3

1 P-64435

Replace the O-ring (Item 1) [Figure 30-40-15].

P-64431
Inspect the poppet (Item 2) and the spring seat (Item 3)
[Figure 30-40-15] for damage or foreign material. Must
The charge relief valve (Item 1) [Figure 30-40-14] is move freely in the relief valve bore.
located on the back of the hydrostatic pump.
Inspect the sealing ring (Item 4) [Figure 30-40-15] and
Remove the charge relief valve. the mating seat in the pump housing for damage or
foreign material.
Installation: Tighten the charge relief valve to 70 N•m
(52 ft-lb) torque. Inspect the spring (Item 5) and the charge relief valve
shims (Item 6) [Figure 30-40-15].

NOTE: 1,0 mm shim = 300 kPa (3 bar) (43.5 psi) in

pressure change. Adding shims increases
charge pressure. Removing shims decreases
charge pressure.

336 of 1052 30-40-8 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-18

Disassembly

Remove the hydrostatic pump / engine assembly from

the loader. (See Engine Removal And Installation on 1
Page 70-10-15.)

Remove the hydrostatic pump. (See Removal And

Installation on Page 30-40-4.)

Figure 30-40-16 1

2
P-90228

Remove the bolts (Item 1) for the swash plate angle

1 sensor (Item 2) [Figure 30-40-18].
1
Figure 30-40-19

P-90226A

Remove the hydraulic controllers (Item 1) [Figure 30-40-

16]. (See Hydraulic Controller Removal And Installation
on Page 30-40-2.)

Figure 30-40-17
3 3
2 2 P-90218

1 1
Remove the O-ring (Item 1) [Figure 30-40-19].

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 30-40-17].

Remove the two bolts (Item 3) and the steel cover (Item
2) [Figure 30-40-17] from both sides.

337 of 1052 30-40-9 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-22

Disassembly (Cont'd)

Figure 30-40-20

P-64464

1
Remove the end housing / rotating group assembly
P-64445 [Figure 30-40-22] from both ends of the pump.

Figure 30-40-23
Remove the bolts (Item 1) from the right end housing
(Item 2) [Figure 30-40-20]. 1

Figure 30-40-21

P-64465

1
Remove O-ring (Item 1) [Figure 30-40-23].
P-64447

Remove the bolts (Item 1) from the left end housing (Item
2) [Figure 30-40-21].

338 of 1052 30-40-10 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-26

Disassembly (Cont'd)

Figure 30-40-24

RIGHT SIDE

B25012

Disassemble the right side rotating group [Figure 30-40-

P-64454 26].

Figure 30-40-27
Remove valve plate (Item 1) [Figure 30-40-24] from the
right side pump.

NOTE: The valve plates are NOT interchangeable

between the right and left sides.

Figure 30-40-25

LEFT SIDE

B25011

Disassemble the left side rotating group [Figure 30-40-

27].

P-64501

Remove valve plate (Item 1) [Figure 30-40-25] from the

left side pump.

NOTE: The valve plates are NOT interchangeable

between the right and left sides.

339 of 1052 30-40-11 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-30

Disassembly (Cont'd)
1
Figure 30-40-28

P-64471

Remove the spherical washer (Item 1) [Figure 30-40-

P-64475 30].

Figure 30-40-31
Remove the pistons (Item 1) [Figure 30-40-28] from the
rotating block.
1
Figure 30-40-29
1

P-64472

Do Not remove the pins (Item 1) [Figure 30-40-31] from

P-64476 the cylinder block.

Remove the pistons (Item 1) [Figure 30-40-29] from the

piston retainer.

340 of 1052 30-40-12 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-34

Disassembly (Cont'd)
2 2
Figure 30-40-32

P109266
2

Figure 30-40-35
P109265

Remove the swash plate (Item 1) from the end cap

housing (Item 2) [Figure 30-40-32].

Remove the link (Item 3) [Figure 30-40-32].

1
Figure 30-40-33

1
P109268

Remove the positioning pin (Item 1) [Figure 30-40-34]

and [Figure 30-40-35].
2
Remove the bearing races (Item 2) [Figure 30-40-34].

P109269

Remove the bearing (Item 1) [Figure 30-40-33].

Remove the positioning wire (Item 2) [Figure 30-40-33].

341 of 1052 30-40-13 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-38

Disassembly (Cont'd)

Figure 30-40-36

LEFT SIDE

1
P-76742

Remove the pump seal (Item 1) [Figure 30-40-38] by

P-64486 inserting a screw into the seal and prying out.

Figure 30-40-39
Figure 30-40-37

RIGHT SIDE 1

P-64488
P-76743

The drive shaft can be tapped out of the end housing with
Remove the snap ring (Item 1) [Figure 30-40-36] and a rubber mallet.
[Figure 30-40-37] from the end housing.
Remove the snap ring (Item 1) and remove the bearing
(Item 2) [Figure 30-40-39].

342 of 1052 30-40-14 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-42

Disassembly (Cont'd)

Figure 30-40-40

P-90231

Rotate the servo piston cover (Item 1) [Figure 30-40-42].

P-64490
Figure 30-40-43

Measure and record servo piston depth at the adjustment

screw [Figure 30-40-40].

Figure 30-40-41

1 1
P-90237

Slide the servo piston assembly out of the bore. [Figure

30-40-43].
P-90232

Remove servo piston bolts (Item 1) [Figure 30-40-41].

343 of 1052 30-40-15 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-46

Disassembly (Cont'd)

Figure 30-40-44 1

2
1 2

P-64496

Remove the servo cover (Item 1) [Figure 30-40-46] from

P-64493 the servo piston.

Remove the O-ring (Item 2) [Figure 30-40-46] from the

Remove the bushings (Item 1), seals and O-rings (Item 2) cover.
[Figure 30-40-44] from the pump housing.
Figure 30-40-47
Figure 30-40-45

1
P-64497
P-64495

Remove snap ring (Item 1) [Figure 30-40-47] from the

Remove the locknut (Item 1) [Figure 30-40-45] from the servo piston.
servo piston.

344 of 1052 30-40-16 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D)

Disassembly (Cont'd)

Figure 30-40-48

1
2

P-64498

Remove the piston stop adjustment mechanism (Item 1)

[Figure 30-40-48] from the servo piston.

Remove the O-ring (Item 2) [Figure 30-40-48].

Figure 30-40-49

2
1

P-64502

Remove the bearings (Item 1) [Figure 30-40-49].

Remove the coupler (Item 2) [Figure 30-40-49].

345 of 1052 30-40-17 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-52

Inspection

Figure 30-40-50

P-64477

Inspect the mating surface of the piston retainer for

P-86718 scoring or scratches (Item 1) [Figure 30-40-52].

Figure 30-40-53
Inspect the valve plates (Item 1) [Figure 30-40-50] for
scratches or scoring. Replace a valve plate if the 1
scratches are deep enough to catch with a fingernail. 1

Figure 30-40-51

P-64472
1

Inspect the pins (Item 1) [Figure 30-40-53]. The pins

must be all the same length.
P-64476

Inspect the pistons for scoring and scratches. The holes

(Item 1) [Figure 30-40-51] in the slippers must not be
plugged.

346 of 1052 30-40-18 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-56

Inspection (Cont’d)

Figure 30-40-54

P109265

Inspect mating surface for the slippers on the swash plate

P-64474 (Item 1) [Figure 30-40-56].

Figure 30-40-57
Inspect the spherical washer for scoring and wear (Item
1) [Figure 30-40-54].
2
Figure 30-40-55

2
1
3

P-64482

Inspect the bearings (Item 1) and machined surfaces

P-64478 (Item 2) [Figure 30-40-57] on swash plate for scratches
or scoring.

Inspect the back surface of the rotating block (Item 1)

[Figure 30-40-55] where the valve plate seals. There
must be no scratches or scoring.

Inspect that the spring (Item 2) and snap ring (Item 3)

[Figure 30-40-55] are not bent or damaged.

347 of 1052 30-40-19 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-60

Inspection (Cont’d)

Figure 30-40-58 1

1
P-64498

Inspect the servo piston stop adjustment (Item 1) [Figure

P-86723 30-40-60] for broken parts.

Figure 30-40-61
Inspect bearing surfaces (Item 1) [Figure 30-40-58] for
scratches or scoring.

Figure 30-40-59

3
1

3 1

P109268

Inspect the positioning pin (Item 1) [Figure 30-40-61] for

P-64488 wear or damage and replace as needed.

Inspect the bearing (Item 1) [Figure 30-40-59].

Inspect wear surfaces (Item 2) for scratches. Inspect the

splines (Item 3) for excessive wear.

348 of 1052 30-40-20 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-64

Assembly

Figure 30-40-62

P-64497
2

Install the snap ring (Item 1) [Figure 30-40-64].

P-64502
Figure 30-40-65

Install the coupler (Item 1) [Figure 30-40-62].

Install the bearings (Item 2) [Figure 30-40-62].

Figure 30-40-63

1
1

2
P-64496

Install the O-ring (Item 1) [Figure 30-40-65] on the servo

cover.

P-64498

Install the piston stop adjustment mechanism (Item 1) in

to the servo piston (Item 2) [Figure 30-40-63].

349 of 1052 30-40-21 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-68

Assembly (Cont’d)

Figure 30-40-66

P-90237

2 Install the servo piston assembly [Figure 30-40-68].

P-64495
Figure 30-40-69

Install the servo cover (Item 1) on the servo piston to the

dimension recorded earlier. Install the locknut (Item 2)
[Figure 30-40-66].

Figure 30-40-67
1

1
2

1
2 P-64466

Align the servo piston with the guide slot (Item 1) [Figure
30-40-69] parallel to the drive shaft center line.

P-64493

Install the bushings (Item 1), seals and O-rings (Item 2)

[Figure 30-40-67] in the pump housing.

350 of 1052 30-40-22 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D)

Assembly (Cont’d)

Figure 30-40-70

1 1

P-90232

Install the bolts (Item 1) [Figure 30-40-70].

Tighten the bolts to 10,4 N•m (7.7 ft-lb) torque.

351 of 1052 30-40-23 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-74

Assembly (Cont’d) LEFT SIDE

Figure 30-40-71 1
2
RIGHT SIDE

1 P-64503

2
Align the timing pin (Item 1) [Figure 30-40-71] and
P-64455 [Figure 30-40-72] in the case housing with the notch
(Item 1) [Figure 30-40-73] and [Figure 30-40-74] that
does not go through the valve plate.
Figure 30-40-72
Align the shoulder of the roller bearing (Item 2) [Figure
LEFT SIDE 30-40-71] and [Figure 30-40-72] with the beveled edge
on the valve plate (Item 2) [Figure 30-40-73] and [Figure
30-40-74].

NOTE: Valve plate must sit FLUSH with the case

housing when properly installed.

Figure 30-40-75

1
2

P-64502
2
1
Figure 30-40-73

RIGHT SIDE

1
2
P-64488

Install the bearing (Item 1) and snap ring (Item 2) [Figure

30-40-75] on the shaft.

Install the shaft in both end housings.

P-64456

352 of 1052 30-40-24 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D)

Assembly (Cont’d)

Figure 30-40-76

LEFT SIDE

P-64486

Install the snap ring (Item 1) [Figure 30-40-76] on both

sides of the pump.

Figure 30-40-77

RIGHT SIDE 2

P-76743

Install the seal (Item 1) and snap ring (Item 2) [Figure

30-40-77] on the right side pump.

353 of 1052 30-40-25 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-80

Assembly (Cont’d)

Figure 30-40-78 1 1

2
2 2

1 P-64480A

Install the swash plate assembly over the shaft and in to

P109266 the end cap housing. The locating wires (Item 1) must
engage the holes (Item 2) [Figure 30-40-80] of the end
cap housing.
Install the positioning pin (Item 1). Install the bearing
races with the tall edge (Item 2) [Figure 30-40-78] of the Figure 30-40-81
race towards the outside of the housing.

Figure 30-40-79

2
2 1

P109273

4 3
P109271 Install the positioning wire (Item 1) into the positioning pin
(Item 2) [Figure 30-40-81].

Install the locating wires (Item 1) through the bearings

and into the hole (Item 2) [Figure 30-40-79] in both sides
of the swash plate.

Install the positioning wire (Item 3) into the hole (Item 4)

[Figure 30-40-79] in the side of the swash plate.

354 of 1052 30-40-26 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-84

Assembly (Cont’d)

Figure 30-40-82

2
1 1

P-64476

Install the pistons (Item 1) [Figure 30-40-84] in the piston

P109274 retainer.

Figure 30-40-85
The swash plate (Item 1) must move smoothly on the
bearings. Install the feedback link (Item 2) [Figure 30-40-
82] on the swash plate.
1
Figure 30-40-83

P-64475

Install the piston / retainer (Item 1) [Figure 30-40-85]

assembly in the cylinder block.
P-64471

Install the ball guide (Item 1) [Figure 30-40-83] on the

cylinder.

355 of 1052 30-40-27 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-88

Assembly (Cont’d)

Figure 30-40-86

1
1

P-64466

Install the end housing assembly into the pump housing.

P-64469A The feedback link (Item 2) [Figure 30-40-87] must
engage the notch in the servo piston (Item 1) [Figure 30-
40-88].
Install the cylinder block / piston assembly (Item 1)
[Figure 30-40-86] on the shaft. Figure 30-40-89

Figure 30-40-87

1 2
1

P-64463

P-64465
Align the dowel pin (Item 1) with the hole in the case
(Item 2) [Figure 30-40-89] as the end cap is installed.
Install the O-ring (Item 1) [Figure 30-40-87].

356 of 1052 30-40-28 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-92

Assembly (Cont’d)
1
Figure 30-40-90

1 1

1 1 P-90218

Install the O-ring (Item 1) [Figure 30-40-92].

P-64445
Figure 30-40-93

Figure 30-40-91

1 1

2
1 1

P-90217

P-64447
Install the swash plate angle sensor (Item 1) into the slot
of the positioning pin (Item 2) [Figure 30-40-93].
Install the bolts (Item 1) [Figure 30-40-90] and [Figure
30-40-91]. Tighten the bolts to 130 N•m (96 ft-lb) torque.

357 of 1052 30-40-29 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D)

Assembly (Cont’d)

Figure 30-40-94

P-90228

Install the bolts (Item 1) [Figure 30-40-94]. Tighten the

bolts to 3,1 N•m (27.4 in-lb) torque.

Figure 30-40-95

2 2

1 1

2 2

P-90227

Install the covers (Item 1) and bolts (Item 2) [Figure 30-

40-95]. Tighten the bolts to 51 N•m (38 ft-lb) torque.

Install the hydraulic controllers. (See Hydraulic Controller

Removal And Installation on Page 30-40-2.)

358 of 1052 30-40-30 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D)

Mechanical Neutral Adjustment

WARNING
The pump mechanical NEUTRAL adjustment sets the
position of the servo piston and pump swash plate
Hydraulic fluid escaping under pressure can have
relative to the hydraulic controller. This procedure should
sufficient force to enter a person’s body by
be followed if the hydrostatic pump has been
penetrating the skin. This can cause serious injury
disassembled for servicing the servo piston and the
and possible death if proper medical treatment by a
setting has been disrupted.
physician familiar with this injury is not received
immediately.
Place the loader on jackstands. (See Procedure on Page W-2145-0290
10-10-1.)

Figure 30-40-96

WARNING 1
1

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

Raise the lift arms, and install an approved lift arm

support device. (See Installing on Page 10-20-2.)

P-64973

WARNING
Connect a hydraulic hose (Item 1) [Figure 30-40-96]
Never work on a machine with the lift arms up unless between port X1 and port X2 on each side of the
the lift arms are secured by an approved lift arm hydrostatic pump, to equalize the pressures on both ends
support device. Failure to use an approved lift arm of the servo pistons.
support device can allow the lift arms or attachment
to fall and cause injury or death. Figure 30-40-97
W-2059-0598

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

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 -
7217666 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
adjustments. Disconnecting the sensors does not have to
be done directly at the sensor, follow the harness back to
find an accessible connector to disconnect. P-90242

Remove the plugs (Item 1) [Figure 30-40-97] from the

MB ports on the front side of the pump, and install 51711
kPa (517 bar) (7500 psi) pressure gauges.

359 of 1052 30-40-31 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-100

Mechanical Neutral Adjustment (Cont’d)

Figure 30-40-98

P-90226A

Loosen the pump NEUTRAL adjustment locknut (Item 1)

P-90227A [Figure 30-40-100].

Start the loader using the Remote Start Tool and run at
Remove the plugs (Item 1) [Figure 30-40-98] from the idle.
MA ports on the bottom of the pump, and install 51711
kPa (517 bar) (7500 psi) pressure gauges.

Figure 30-40-99 WARNING

Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297

1 1
Figure 30-40-101

1 1

P-90243

Remove the drive hoses from the A and B ports (Item 1)

[Figure 30-40-99]. Plug the ports with metal caps. The
1
caps must be able to handle at least 51711 kPa (517 bar)
(7500 psi). Plugging the A and B ports eliminates
leakage at the drive motors from causing errors in the P-90238
pump mechanical NEUTRAL setting.

Turn the adjustment screw (Item 1) [Figure 30-40-101]

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.

360 of 1052 30-40-32 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-104

Mechanical Neutral Adjustment (Cont’d)

Figure 30-40-102

P-90238
1

While holding the adjustment screw (Item 1) in position,

P-90238 tighten the locknut (Item 2) [Figure 30-40-104] to 30 N•m
(22 ft-lb) torque.

Turn the adjustment screw (Item 1) [Figure 30-40-102] Shut the loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the hydraulic hose from the X1 and X2 ports on
adjustment screw. the pump. Install the plugs and tighten to 25 N•m (18 ft-
lb) torque.
Figure 30-40-103
Remove the pressure gauges from the MA and MB ports
on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.

NOTE: The Hydraulic Controller NEUTRAL

Adjustment must be performed whenever the
Mechanical NEUTRAL Adjustment is done.
(See Hydraulic Controller Neutral Adjustment
on Page 30-40-34.)

P-90238

Turn the adjustment screw (Item 1) [Figure 30-40-103]

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.

361 of 1052 30-40-33 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-105

Hydraulic Controller Neutral Adjustment

The hydraulic controller NEUTRAL adjustment aligns the

pump swash plate and the control spool so that a zero 1
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, removed or after the pump mechanical
NEUTRAL setting is adjusted. The pump mechanical
NEUTRAL setting must be correct before performing the
hydraulic controller NEUTRAL adjustments.

NOTE: Procedure is shown for the left side hydraulic 1

controller. Procedure is the same for the right P-90239
side hydraulic controller, with the exception
of the following procedures: Disconnect the
electrical connectors for the right side Disconnect the wire harness (Item 1) [Figure 30-40-105]
hydraulic controller and connect pressure from the controller being adjusted.
gauges in the X1 and X2 ports on the right
side of the pump. Figure 30-40-106

Place the loader on jackstands. (See Procedure on Page

10-10-1.)

1
WARNING
2
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-90226A
Raise the lift arms, and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Remove the X1 plug (Item 1) and X2 plug (Item 2)
Raise the operator cab. (See Raising on Page 10-30-1.) [Figure 30-40-106] from the side of the hydrostatic pump
being adjusted.
Connect the Remote Start Tool. (See REMOTE START
TOOL KIT - MEL1563 on Page 10-60-1.) or (See
REMOTE START TOOL (SERVICE TOOL) KIT -
7217666 on Page 10-61-1.)

362 of 1052 30-40-34 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D) Figure 30-40-109

Hydraulic Controller Neutral Adjustment (Cont’d)

Figure 30-40-107

P-90236

Turn the adjustment screw (Item 1) [Figure 30-40-109]

P-64975 clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.
Install 3447 kPa (34 bar) (500 psi) pressure gauges in the
X1 and X2 ports [Figure 30-40-107]. Figure 30-40-110

Figure 30-40-108

1
1

P-90236

P-90236
Turn the adjustment screw (Item 1) [Figure 30-40-110]
counterclockwise, until the other gauge registers an
Loosen the screw (Item 1) [Figure 30-40-108]. increase in system pressure. Mark the position of the
adjustment screw.
Start the loader using the Remote Start Tool and run at
an idle.

WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297

363 of 1052 30-40-35 T870 Service Manual

HYDROSTATIC PUMP (SJC AND SCPA) (CONT'D)

Hydraulic Controller Neutral Adjustment (Cont’d)

Figure 30-40-111

P-90236

Turn the adjustment screw (Item 1) [Figure 30-40-111]

clockwise to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.

Figure 30-40-112

1
2

P-90236

While holding the adjustment screw (Item 1) in position,

tighten the locking screw (Item 2) [Figure 30-40-112] to
6,1 N•m (4.5 ft-lb) torque.

Shut the loader OFF.

Remove the pressure gauges from the X1 and X2 ports

on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.

Connect the wire harness to the controller.

Perform a controller calibration procedure. (See

ELECTRICAL / HYDRAULIC CONTROLS (SJC) on Page
60-140-1.)

364 of 1052 30-40-36 T870 Service Manual

DRIVE BELT Figure 30-50-3

Belt Adjustment
1
The drive belt does not need adjustment. The belt has a
spring loaded idler which constantly maintains the correct
belt tension. 2

Stop Adjustment

See your SERVICE SCHEDULE for the correct interval to

check the idler stop adjustment. (See SERVICE
SCHEDULE on Page 10-70-1.)

Stop the engine and open the rear door.

P121578A

Figure 30-50-1
Allow the stop arm (Item 1) to contact the top of the
spring loaded idler (Item 2) [Figure 30-50-3].

Tighten the spring loaded idler adjustment bolt (Item 1)

[Figure 30-50-2] to 105 – 115 N•m (78 – 85 ft-lb) torque.

P121107A

The spring loaded idler is located above the battery on

the left side of the engine [Figure 30-50-1].

Figure 30-50-2

P121579

Loosen the spring loaded idler adjustment bolt (Item 1)

[Figure 30-50-2].

365 of 1052 30-50-1 T870 Service Manual

DRIVE BELT (CONT’D) Figure 30-50-6

Belt Replacement
1
Stop the engine and open the rear door.

Remove the battery. (See Removal And Installation on

Page 60-20-1.)

Figure 30-50-4
2

P109783

Loosen the spring loaded idler adjustment bolt (Item 1).

Insert a breaker bar (Item 2) [Figure 30-50-6] into the
slot provided in the stop arm as shown and push the
breaker bar down to release tension on the drive belt.

Tighten the adjustment bolt (Item 1) [Figure 30-50-6] to

P121086
hold the spring loaded idler off the drive belt.

Remove the drive belt from the hydrostatic pump pulley

Remove the drive belt shield bolt (Item 1) [Figure 30-50- and flywheel pulley. Inspect the pulleys for wear.
4].
Install new drive belt.
Figure 30-50-5
Loosen the spring loaded idler adjustment bolt (Item 1)
[Figure 30-50-6] and allow the idler to contact the drive
belt.
1
2 Continue the procedure on the next page.

P121188

Do NOT loosen the drive belt shield mounting bolts (top

bolt shown) (Item 1). Slide the drive belt shield (Item 2)
[Figure 30-50-5] 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 30-50-5].

366 of 1052 30-50-2 T870 Service Manual

DRIVE BELT (CONT’D) Position the drive belt shield over the drive belt shield
mounting bolts. Slide the drive belt shield toward the front
Belt Replacement (Cont’d) of the loader to fully seat the shield onto the top and
bottom mounting bolts (Items 1 and 2) [Figure 30-50-8].
Figure 30-50-7
Figure 30-50-9

1 1

P115669

Adjust a torque wrench for 54,2 N•m (40 ft-lb). Insert the
P121086
torque wrench (Item 2) [Figure 30-50-7] into the slot
provided in the stop arm as shown and move the torque
wrench up until the correct torque is indicated. Install the drive belt shield bolt (Item 1) [Figure 30-50-9].

Maintain torque on the stop arm and tighten the spring Install the battery. (See Removal And Installation on
loaded idler adjustment bolt (Item 1) [Figure 30-50-7] to Page 60-20-1.)
105 – 115 N•m (78 – 85 ft-lb) torque.
Close the rear door.
NOTE: This procedure is required to preload a new
drive belt in order to achieve the correct stop NOTE: The stop arm MUST be adjusted after 50 hours
adjustment after the initial belt break-in operation with the new drive belt. (See Stop
period. Adjustment on Page 30-50-1.)

Figure 30-50-8 See the SERVICE SCHEDULE for the correct

service interval after the initial 50 hour
Top Mounting Bolt adjustment. (See SERVICE SCHEDULE on
Page 10-70-1.)

P107207A

Bottom Mounting Bolt

P107206

367 of 1052 30-50-3 T870 Service Manual

DRIVE BELT (CONT’D) Figure 30-50-11

Tensioner Pulley Removal And Installation

Stop the engine and open the rear door.

Remove the battery. (See Removal And Installation on

Page 60-20-1.) 1

Remove the drive belt. (See Belt Replacement on Page

30-50-2.)

NOTE: The procedure on this page may need to be

preformed to aid in the removal of the
tensioner pulley bolts.
P115939
Figure 30-50-10

Remove the rear engine mount bolt (Item 1) [Figure 30-

50-11].

Installation: Tighten the mounting bolt to 122 - 135 N•m

(90 - 100 ft-lb) torque.
1
Figure 30-50-12

P115941

Loosen the left side engine mount bolt (Item 1)[Figure

30-50-10]. Do not remove the bolt. 1

Installation: Tighten the mounting bolt to 122 - 135 N•m

(90 - 100 ft-lb) torque.
P121203

Install a ratchet strap or pistol grip clamp (Item 1) [Figure

30-50-12] and apply enough pressure to allow removal of
the tensioner pulley bolts.

368 of 1052 30-50-4 T870 Service Manual

DRIVE BELT (CONT’D) Figure 30-50-15

Tensioner Pulley Removal And Installation (Cont’d)

NOTE: Engine removed for photo clarity.

Figure 30-50-13 1 2

3 1

P121786

Disassemble the tensioner assembly as shown [Figure

30-50-15].

P121262 Inspect the parts for wear and replace as needed.

NOTE: The wheel (Item 1) and the tensioner arm (Item

Remove the adjustment bolt and the spacer (Item 1), the 2) [Figure 30-50-15] are not serviceable and
mounting bolt (Item 2) and remove the stop arm (Item 3) must be replaced as a complete assembly.
and the tensioner assembly (Item 4) [Figure 30-50-13].

Installation: Tighten the adjustment bolt and the

mounting bolt to 105 - 115 N•m (78 - 85 ft-lb) torque.

Figure 30-50-14

P115949

Inspect the pivot bushing (Item 1) [Figure 30-50-14] for

wear or damage and replace as needed.

Installation: Use MEL1733 to aid in pivot bushing

installation.

369 of 1052 30-50-5 T870 Service Manual

370 of 1052 30-50-6 T870 Service Manual
TWO-SPEED / BRAKE VALVE

Description

Figure 30-60-1

P109064

The two-speed / brake valve (Item 1) [Figure 30-60-1] is

located on top of the chaincase in front of the hydrostatic
pump. The high range is selected by a switch located on
the hand control.

When the high range is selected, the two-speed solenoid

is energized by the Bobcat Controller. The valve shifts
and directs charge pressure oil to the shift spool in each
motor. The charge pressure hydraulic oil shifts the spools
allowing the motors to move into high range. When low
range is selected, the solenoid is de-energized and the
shift spools are spring returned to low range.

371 of 1052 30-60-1 T870 Service Manual

TWO-SPEED / BRAKE VALVE (CONT'D) Figure 30-60-2

Valve Block Removal And Installation

DANGER 1

P109064
P-90328

AVOID DEATH Disconnect and plug the four hydraulic hoses (Item 1)
• Disconnecting or loosening any hydraulic [Figure 30-60-2] from the two-speed brake valve.
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

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 operator cab. (See OPERATOR CAB on Page

10-30-1.)

Mark all hydraulic hoses for proper installation.

372 of 1052 30-60-2 T870 Service Manual

TWO-SPEED / BRAKE VALVE (CONT'D)

Valve Block Removal And Installation (Cont’d)

Figure 30-60-3

P109065

Disconnect and plug the two hydraulic hoses (Item 1)

[Figure 30-60-3] from the two-speed brake valve.

Figure 30-60-4

P109059A

Remove the tie-strap (Item 1) and disconnect the wire

harnesses (Item 2) [Figure 30-60-4].

Remove the two mounting bolts (Item 3) [Figure 30-60-4]

from the valve block.

Remove the two-speed / brake block from the loader.

373 of 1052 30-60-3 T870 Service Manual

TWO-SPEED / BRAKE VALVE (CONT'D) Figure 30-60-7

Valve Block Disassembly And Assembly

Figure 30-60-5

1
1

P107100

Use a test meter and test the solenoid coils (Item 1)

P107098 [Figure 30-60-7] for resistance.

The resistance value for the solenoid coil can be found on

Mark all hydraulic hoses and fittings for proper the electrical schematic.
installation.
Figure 30-60-8
Remove the hydraulic fittings (Item 1) [Figure 30-60-5]
from the valve block.

Figure 30-60-6
1

2
P107101
3

Use a test meter and test the solenoid coils (Item 1)

P107099 [Figure 30-60-8] for resistance.

The resistance value for the solenoid coil can be found on

Remove the two bolts (Item 1) from the brake valve the electrical schematic.
solenoid (Item 2) [Figure 30-60-6].
Assembly: Always install new O-rings [Figure 30-60-8].
Remove the electrical solenoid nut (Item 3) from the
make-up solenoid (Item 4) [Figure 30-60-6].

Assembly: Tighten the bolts (Item 1) [Figure 30-60-6] to

2,7 N•m (2 ft-lb) torque.

Assembly: Tighten the nut (Item 3) [Figure 30-60-6] to 6

N•m (53 in-lb) torque.

374 of 1052 30-60-4 T870 Service Manual

TWO-SPEED / BRAKE VALVE (CONT'D)

Valve Block Disassembly And Assembly (Cont'd)

Figure 30-60-9

P107104

Remove the make-up solenoid (Item 1) [Figure 30-60-9]

from the valve block.

Assembly: Tighten the solenoid valve to 27 N•m (20 ft-

lb) torque.

Figure 30-60-10

1
1

2 2 2

P107103

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

[Figure 30-60-10].

375 of 1052 30-60-5 T870 Service Manual

376 of 1052 30-60-6 T870 Service Manual
DRAIN MANIFOLD Figure 30-70-2

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
2

IMPORTANT 1
2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
P121211
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 30-70-2].

Raise the operator cab. (See Raising on Page 10-30-1.) Remove the two hoses (Item 2) [Figure 30-70-2].

Drain the hydraulic reservoir. (See Removing And Mark and cap all hoses.
Replacing Hydraulic Fluid on Page 10-120-2.)
Figure 30-70-3
Figure 30-70-1

1 1
1

P121212
P121210

Remove the two hoses (Item 1) [Figure 30-70-3].

Remove the three hoses (Item 1) [Figure 30-70-1] from
the drain manifold. Remove the two bolts and nuts (Item 2) [Figure 30-70-1].

Mark and cap all hoses and. Mark and cap all hoses.

377 of 1052 30-70-1 T870 Service Manual

378 of 1052 30-70-2 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 (Earlier Models With Two Track Tension Fittings) . . . . . . . . . . . . 40-20-4
Adjusting Tension (Later Models With One Track Tension Fitting) . . . . . . . . . . . . . . 40-20-5
Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-6
Idler (Front) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-8
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-11
Idler (Rear) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-13
Roller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-13
Leaf Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-14
Sprocket Removal And Installation (Single Speed) . . . . . . . . . . . . . . . . . . . . . . . . 40-20-15
Sprocket Removal And Installation (Two-Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-15
Track Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-16

TRACK MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

Track Damage Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

379 of 1052 40-01 T870 Service Manual

380 of 1052 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 10-20-2.)
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
4
located on the left panel.
3
Block Removal And Installation
4

2
DANGER 1

P107493

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 three hydraulic hoses (Item 2)
AVOID DEATH [Figure 40-10-2].
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure Remove and cap the hydraulic tubeline (Item 3) [Figure
can cause lift arms to drop. 40-10-2].
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm Remove the two mount bolts (Item 4) [Figure 40-10-2].
support. Replace if damaged.
D-1009-0409 Remove the brake block from the loader.

381 of 1052 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
Replace the O-rings (Item 1) and back-up ring (Item 2)
P-85431 [Figure 40-10-5] on the solenoid valve.

Check the screens (Item 3) [Figure 40-10-5] and clean

Loosen the electrical brake solenoid nut (Item 1) and the with solvent.
three fittings (Item 2) [Figure 40-10-3].
Assembly: Tighten the solenoid valve to 21,7 - 27 N•m
Assembly: Tighten the solenoid nut to 5,4 - 6,8 N•m (48 (16 - 20 ft-lb) 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.

382 of 1052 40-10-2 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION)

Description

Figure 40-20-1

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].

383 of 1052 40-20-1 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Checking Tension
SUSPENSION) (CONT’D)
Correct track tension is important for good performance
Description (Cont’d) and to prevent the tracks from derailing or wearing
prematurely.
Figure 40-20-2
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 40-20-3

P107800

A bleed tool [Figure 40-20-2] is available and

recommended to decrease track tension. The bleed tool
will direct the flow of grease to aid in cleanup. 1

The bleed tools are sized differently:

P100255B

Part number 6675936 - Used for machines with two

track tension fittings. Raise one side of the loader and put jackstands at the
front and rear of the loader frame so that the track is
Part number 7277225 - Used for machines with one about 76,2 mm (3 in) off the ground [Figure 40-20-3].
track tension fitting. Lower the loader to the jackstands. Be sure the
jackstands do not touch the tracks.

Measure the track sag at either middle track roller (Item

1) [Figure 40-20-3]. The correct gap is 13 mm (1/2 in).

384 of 1052 40-20-2 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER
SUSPENSION) (CONT’D)

Checking Tension (Cont’d)

Figure 40-20-4

P-85379B

Figure 40-20-5

13 mm Track
Roller
(1/2 in)

Track
B-18896C

DO NOT put your fingers into the pinch points between

the track and the roller. Use a 13 mm (1/2 in) bolt, dowel
or block to check the gap [Figure 40-20-4] and [Figure
40-20-5].

WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0903

385 of 1052 40-20-3 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-7
SUSPENSION) (CONT’D)

Adjusting Tension (Earlier Models With Two Track

Tension Fittings)

Figure 40-20-6
2 1
1
2

P-109765

Pressure must be released from the grease cylinder to

decrease track tension.
1
Install the bleed tool (6675936) on the bleed fitting (Item
P-76325A 1), adjust and tighten the collar (Item 2) [Figure 40-20-7]
to fit behind the edge of the access cover.
Loosen the access cover bolts and pivot the access cover
open [Figure 40-20-6]. Figure 40-20-8

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 40-20-6] is used to remove grease. 1

Increase Track Tension

Add grease to the grease fitting (Item 1) [Figure 40-20-6]

until the track adjustment is correct [Figure 40-20-4] and
[Figure 40-20-5].

NOTE: Do not remove grease fitting unless pressure P-109764

is released using the bleed fitting. (See
[Figure 40-20-7] on Page 40-20-4)
Tighten the access cover bolt (Item 1) [Figure 40-20-8]
If replacement is necessary, always replace to secure the tool.
grease fitting (Item 1) [Figure 40-20-6] 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 40-20-8]
until the track adjustment is correct [Figure 40-20-4] and
Decrease Track Tension [Figure 40-20-5].

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

386 of 1052 40-20-4 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Pressure must be released from the grease cylinder to
SUSPENSION) (CONT’D) decrease track tension.

Adjusting Tension (Later Models With One Track Figure 40-20-10

Tension Fitting)

Figure 40-20-9

1
2

P109765B

1
Install the bleed tool (7277225) on the track tension fitting
P-76325C (Item 1), adjust and tighten the collar (Item 2) [Figure 40-
20-10] to fit behind the edge of the access cover.
Loosen the access cover bolts and pivot the access cover
open [Figure 40-20-9]. Figure 40-20-11
Increase Track Tension

Add grease to the track tension fitting (Item 1) [Figure

40-20-6] until the track adjustment is correct [Figure 40-
20-4] and [Figure 40-20-5].
1
NOTE: Take care if using a pneumatic grease gun
because high pressure can damage the
grease fitting. Connect the pneumatic grease
gun to a regulated air supply set at the lowest
setting and slowly increase the air pressure
until the grease fitting starts taking grease.

NOTE: Do not remove track tension fitting unless P109764

pressure is released (See [Figure 40-20-10] on
Page 40-20-5).
Tighten the access cover bolt (Item 1) [Figure 40-20-11]
NOTE: If replacement is necessary, always replace to secure the tool.
track tension fitting (Item 1) [Figure 40-20-9]
with genuine Bobcat Parts. The fitting is a Turn the tool 90° counterclockwise and let the grease
special fitting designed for high pressure. flow into a container. Release pressure [Figure 40-20-
Decrease Track Tension 11] until the track adjustment is correct [Figure 40-20-4]
and [Figure 40-20-5].

Tighten the track tension fitting to 24 -30 N•m (18 -22 ft-
WARNING lb) torque. Pivot the access cover closed and tighten the
access cover bolts.

HIGH PRESSURE GREASE CAN Raise the loader. Remove the jackstands. Repeat the
CAUSE SERIOUS INJURY procedure for the other track. Dispose of grease in an
• Do not loosen grease fitting. environmentally safe manner.
• Do not loosen bleed fitting more than 1 - 1/2
turns.
W-2781-0109

387 of 1052 40-20-5 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER
SUSPENSION) (CONT’D)

Track Removal And Installation IMPORTANT

Fluid such as engine oil, hydraulic fluid, coolants,
grease, etc. must be disposed of in an
DANGER 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
to flow out faster when lifting the track in the next step.
P-90328
You MUST pivot the access cover against the MEL tool
AVOID DEATH and tighten the mount bolt (Item 1) [Figure 40-20-8]
• Disconnecting or loosening any hydraulic before continuing.
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. Figure 40-20-12
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
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 1

support device. (See Installing on Page 10-20-2.)

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. 12].
W-2059-0598
Tighten the bleed fitting using the MEL1560 tool (Item 1)
[Figure 40-20-12].
Decrease the track tension. (See Adjusting Tension
(Earlier Models With Two Track Tension Fittings) on Page
40-20-4.)

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).

388 of 1052 40-20-6 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-14
SUSPENSION) (CONT’D)

Track Removal And Installation (Cont’d)

Figure 40-20-13

P-85369

With a chain hoist lift the track clear of the drive sprocket
and remove the track from the loader [Figure 40-20-14].
P-85370
Installation: Completely retract the front idler / track
tensioner.
With pry bars, pry the track up and over the front idler
[Figure 40-20-13]. 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 40-20-23] before adjusting the track.

Adjust the track to the proper tension. (See Adjusting

Tension (Earlier Models With Two Track Tension Fittings)
on Page 40-20-4.)

389 of 1052 40-20-7 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-17
SUSPENSION) (CONT’D)

Idler (Front) Removal And Installation

1 1
Remove the track. (See Track Removal And Installation
on Page 40-20-6.)

Figure 40-20-15

P-73967

Installation: Two short 9,5 mm (3/8 in) bolts (Item 1)

1 [Figure 40-20-17] 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
remove the bolts after track tension has been
set.
Slide the front idler wheel out of the track housing
[Figure 40-20-15].

NOTE: The notch on the front idler wheel frame (Item

1) [Figure 40-20-15] is toward the top of the
track housing for installation.

Figure 40-20-16

P-76051

Installation: Make sure the pins (Item 1) [Figure 40-20-

16] on the front idler wheel frame engage the holes in the
track tensioner.

390 of 1052 40-20-8 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-20
SUSPENSION) (CONT’D)

Idler (Front) Removal And Installation (Cont’d)

Figure 40-20-18

P-76325

Installation: Track tensioner must be seated properly

against the end of the track housing [Figure 40-20-20].

P-76844

Slide the track tensioner (Item 1) [Figure 40-20-18] out

of the track housing.

Installation: Track tensioner must be oriented as shown

in [Figure 40-20-18] before sliding it into the track
housing.

Figure 40-20-19

1 2
P-76850

Installation: Track tensioner (Item 1) must slide into the

guide tube (Item 2) [Figure 40-20-19].

391 of 1052 40-20-9 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-23
SUSPENSION) (CONT’D)

Idler (Front) Removal And Installation (Cont'd) CORRECT

Figure 40-20-21

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-
23].

Figure 40-20-22

WRONG

P-85014

Installation: [Figure 40-20-21] and [Figure 40-20-22]

shows the grease tube (Item 1) misaligned and not
seated properly against the coil spring assembly (Item 2).
[Figure 40-20-23] shows the grease tube (Item 1) and
the coil spring assembly (Item 2) properly assembled.

392 of 1052 40-20-10 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-25
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
AVOID INJURY OR DEATH (Item 3), and wear ring (Item 4) [Figure 40-20-25] from
• Spring loaded components under pressure can the grease tube.
cause serious injury or death.
• Do not disassemble the coil spring assembly Installation: Apply oil to new O-ring, back-up ring, seal,
W-2617-1004 and wear ring before installation.

Figure 40-20-24 Installation: Apply grease to area between seal and O-

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 40-20-24].

393 of 1052 40-20-11 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-27
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 40-20-27].
AVOID INJURY OR DEATH
• Spring loaded components under pressure can 1. Coil Spring Assembly
cause serious injury or death. 2. O-ring 
• Do not disassemble the coil spring assembly 3. Chrome Shaft
W-2617-1004 4. Seal
5. Back-up Ring
6. O-ring
Figure 40-20-26 7. Wear Ring
1 8. Grease Tube

NOTE: The O-ring (Item 2) is used to secure the

chrome shaft (Item 3) to the coil spring
assembly (Item 1) [Figure 40-20-27] 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-

20-26] is only sold as a complete assembly
from Bobcat Parts.

394 of 1052 40-20-12 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 40-20-6.)

Remove the track. (See Track Removal And Installation Figure 40-20-29
on Page 40-20-6.)

Figure 40-20-28

1
1

2
2 P-85374

P-76847 Remove the bolt and washer (Item 1) [Figure 40-20-29]

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 40-20-28].
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-
28].

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.

395 of 1052 40-20-13 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Installation: Tighten the leaf spring bolts (Item 2)
SUSPENSION) (CONT’D) [Figure 40-20-30] and (Item 1) [Figure 40-20-31] to
406,7 N•m (300 ft-lb) torque.
Leaf Spring Removal And Installation
Figure 40-20-32
Remove the track from the loader. (See Track Removal
And Installation on Page 40-20-6.)

Figure 40-20-30

1
3
P-76930

Remove the leaf spring assembly [Figure 40-20-32] from

P-85375 the track housing.

NOTE: The leaf spring assembly [Figure 40-20-32] is

Remove the roller bolt and washer (Item 1) [Figure 40- only sold as a complete left-hand or right
20-30] from the roller shaft. (Both ends of the roller hand assembly from Bobcat Parts.
shaft.)
Figure 40-20-33
Remove the roller from the track housing.

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 40-20-30]

from the leaf spring mounts. (Both sides of the track
housing.) 1

Figure 40-20-31

P-76027

The upper and lower leaf spring mounts are wider on one
1 side to prevent the leafs from rubbing on the track
housing during operation.

Installation: The leaf springs are installed correctly

when there is a slight gap (Item 1) [Figure 40-20-33]
P-85377 between the leafs and the track housing. (Cutaway view
shown for clarity.) The gap is easily seen at the roller end
of the leaf spring (Item 3) [Figure 40-20-30].
Access the front, inside leaf spring assembly bolts (Item
1) [Figure 40-20-31] from underneath the loader through
an access hole in the track housing.

396 of 1052 40-20-14 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Sprocket Removal And Installation (Two-Speed)
SUSPENSION) (CONT’D)
Figure 40-20-35
Sprocket Removal And Installation (Single Speed)

Figure 40-20-34 1

2
2
1
2

2
2
P100737A
2

P-85407 Remove the eight nuts (Item 1) [Figure 40-20-35] and

remove the drive sprocket from the motor.

Remove the six nuts (Item 1) [Figure 40-20-34] and NOTE: Install four (1/2” - 13UNC x 3 in) long bolts in
remove the drive sprocket from the motor. the sprocket holes (Item 2) [Figure 40-20-35]
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 40-20-34] 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 -

221 ft-lb) torque.

397 of 1052 40-20-15 T870 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (ROLLER Figure 40-20-37
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 40-20-6.)

Remove the hydrostatic motor from the track housing.

(See Removal And Installation on Page 30-20-2.)

Support the track housing.

P-76864
Figure 40-20-36

At the rear of the loader remove the two mount bolts

(Item 1) [Figure 40-20-37].

Installation: Tighten the mount bolts to 450 N•m (330 ft-

lb) torque.

1 Figure 40-20-38

1
1

P100387

Remove the six mounting bolts (Item 1) [Figure 40-20-

36] 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 40-20-38].

Remove the track housing from the loader.

Installation: Tighten the mount bolts to torque.

398 of 1052 40-20-16 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
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 Checking Tension on Page 40-20-2.)

Avoiding quick turns on bumpy and rocky fields.

Drive carefully to avoid having stones and other

articles clog the rubber tracks.

399 of 1052 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

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 Track Removal And Installation
on Page 40-20-6.)
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].

400 of 1052 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:
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].

401 of 1052 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.)

Prevention: Remove the sprocket. (See Sprocket Removal And

Installation (Single Speed) on Page 40-20-15.) or (See
Similar to the prevention against the cutting of the steel Sprocket Removal And Installation (Two-Speed) on Page
cords: 40-20-15.)

Recommended track tension should be periodically

checked. (See Checking Tension on Page 40-20-2.)

Quick turns on bumpy and rocky fields should be

avoided.

402 of 1052 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 from the
Damage: 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.

403 of 1052 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
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.

404 of 1052 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.
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.

405 of 1052 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

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.

406 of 1052 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
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.

407 of 1052 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
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.

408 of 1052 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:

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.

409 of 1052 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

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.

410 of 1052 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
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 . . . . . . . . . . . . . . . . . . . . . . . 50-41-6

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
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-2

411 of 1052 50-01 T870 Service Manual

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
Tailgate Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-4

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
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
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) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

ACCESS PANEL (INSIDE) (SCPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1

412 of 1052 50-02 T870 Service Manual

WINDOW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Rear Window Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Removal (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Installation (Rubber Cord) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-2
Removal And Installation (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-4
Disassembly And Assembly (Latches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-4

WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

WINDOW (SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1

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

HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1

FAN DUCT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190-1

413 of 1052 50-03 T870 Service Manual

414 of 1052 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

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-85652A

Remove the seat bar mounting nuts (Item 1) [Figure 50-

10-2] (both sides).

415 of 1052 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

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.

416 of 1052 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)
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.

417 of 1052 50-10-3 T870 Service Manual

418 of 1052 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
death. 1
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].

AVOID INJURY OR DEATH
Figure 50-20-3
Attach a chain hoist to the grab handles of the
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

Figure 50-20-1
2
1

1 3

P-85652A

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).

419 of 1052 50-20-1 T870 Service Manual

OPERATOR CAB (CONT’D) Removal And Installation

Gas Spring Bracket Disassembly And Assembly Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-40-
Figure 50-20-4 2.)

Remove the evaporator / heater cover. (See Removal on

Page 80-150-1.)

3 Figure 50-20-5

1 1
1

2
2

P-85661 1

Remove the clevis (Item 1) from both ends, and the outer
housing (Item 2) from the gas spring (Item 3) [Figure 50- 1
20-4].
P100879A
Installation: Apply a small amount of thread-locker on
the threads of the gas spring rod before installing the
clevis (Item 1) [Figure 50-20-4]. Disconnect the expansion / heater unit wiring connectors
(Item 1) [Figure 50-20-5].

Remove the two heater hoses (Item 2) [Figure 50-20-5].

WARNING
NOTE: Cap the heater hoses and the heater valve
AVOID INJURY with plugs to prevent coolant loss from the
Cylinders for raising and lowering operator cab have system.
gas under pressure. Do not open cylinder. Only
qualified service personnel can remove the cylinder.
W-2112-0987

420 of 1052 50-20-2 T870 Service Manual

OPERATOR CAB (CONT’D) Figure 50-20-7

Removal And Installation (Cont’d)

Figure 50-20-6
1

1
1 P121250

Disconnect the cab harness connectors (Item 1) [Figure

P103082 50-20-7].

Figure 50-20-8
Disconnect the two A/C hoses (Item 1) [Figure 50-20-6].

NOTE: Cap and plug the hoses and expansion valve

fittings with proper A/C caps and plugs.

Installation: Tighten the A/C hoses to 30 N•m (22 ft-lb)

torque.

WARNING 1

AVOID INJURY OR DEATH

Attach a chain hoist to the grab handles of the
P-85658
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 Remove the two cab mount bolts and nuts (Item 1)
could cause injury or death. [Figure 50-20-8] from both sides of the cab.
W-2760-0309

Installation: Tighten the cab mount bolts and nuts to

Remove the operator cab gas spring(s). (See Gas Spring 24,4 - 29,8 N•m (18 - 22 ft-lb) torque.
Removal And Installation on Page 50-20-1.)

NOTE: Use the hoist connected to the operator cab

grab handles to lower or (raise) the operator
cab when the gas spring(s) are disconnected.

421 of 1052 50-20-3 T870 Service Manual

OPERATOR CAB (CONT’D)

Removal And Installation (Cont’d)

Figure 50-20-9

P-85662

Using a strap and a hoist remove the cab from the loader.
[Figure 50-20-9]

422 of 1052 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
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.

423 of 1052 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.

Figure 50-30-5

P-85772

Remove the nut (Item 1) [Figure 50-30-5] from the seat

belt mount.

Remove the seat belt.

424 of 1052 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- Remove the two screws (Item 1) [Figure 50-30-9] and tilt
30-7]. the seat back to the upright position.

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.

425 of 1052 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].

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].

426 of 1052 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].

Figure 50-30-14

P-85787

Remove the shoulder harness retractor (Item 1) [Figure

50-30-14].

427 of 1052 50-30-5 T870 Service Manual

428 of 1052 50-30-6 T870 Service Manual
BOB-TACH (HAND LEVER) Removal And Installation

Description Figure 50-40-1

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.
1
The Bob-Tach is located on the front of the loader
connected to the loader lift arms.

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.

Figure 50-40-2

P-85649

Remove the rod end pivot pin (Item 1) [Figure 50-40-2].

429 of 1052 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

P-31405

1 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).

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].

430 of 1052 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. Figure 50-40-10

Installation: Tighten the retainer nut and bolt (Item 1)

[Figure 50-40-6] and [Figure 50-40-7] to 446 N•m (330
ft-lb) torque.

Figure 50-40-8

2
P-85665

Remove the washer and spring, (Item 1) and the lever

1 assembly (Item 2) [Figure 50-40-10].

P-31407

With a 22,2 mm (0.875 in) punch (Item 1) [Figure 50-40-

8] and a hammer, drive the pivot pin out of the lift arm
and Bob-Tach.

Remove the Bob-Tach from the loader.

NOTE: MEL1685 - Pivot Point Tapered Reamer is

available to ream out tapered bore if
necessary.

431 of 1052 50-40-3 T870 Service Manual

BOB-TACH (HAND LEVER) (CONT'D) Figure 50-40-13

Lever And Wedge Disassembly And Assembly

(Cont'd)

Figure 50-40-11

35,3 mm
(1.39 in) 1

P-85667

Remove the wedge (Item 1) [Figure 50-40-13] out the

bottom of the Bob-Tach.
P127544
Always replace bent or broken wedges.

Installation: Tighten the lever mounting nut until the Earlier Design
spring is compressed to 35,3 mm (1.39 in) [Figure 50-
40-11]. Figure 50-40-14

Figure 50-40-12
4
3

2
1
1

P19287

P-85666
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) are damaged, put the assembly in a
Use a punch and hammer to remove the roll pin (Item 1) vise. Loosen and remove the bolt (Item 1) [Figure 50-40-
[Figure 50-40-12] from the Bob-Tach wedge and spring 14]. Replace the worn or damaged parts as needed.
clevis.
Assembly: Clean the threads and apply Loctite® 242 to
Remove the spring clevis assembly (Item 2) [Figure 50- the bolt (Item 1) [Figure 50-40-14], tighten to 125 - 135
40-12]. N•m (90 - 100 ft-lb) torque.

432 of 1052 50-40-4 T870 Service Manual

BOB-TACH (HAND LEVER) (CONT'D) Pivot Pin Bushing And Seal Removal And Installation

Lever And Wedge Disassembly And Assembly Figure 50-40-16

(Cont'd)

Later Design

Figure 50-40-15 2 1

4
3
2
1

P-85669

Remove the Bob-Tach. (See Removal And Installation on

Page 50-40-1.)
P121303
Use a seal pick to remove seal (Item 1) [Figure 50-40-
16] from the Bob-Tach.
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) are damaged, put the assembly in a Remove and replace bushing (Item 2) [Figure 50-40-16]
vise. Loosen and remove the bolt (Item 1) [Figure 50-40- with a driver tool and hammer.
15]. Replace the worn or damaged parts as needed.
Figure 50-40-17
Assembly: Clean the threads and apply Loctite® 242 to
the bolt (Item 1) [Figure 50-40-15], tighten to 48 - 54 3
N•m (35 - 40 ft-lb) torque.

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 50-40-17].

433 of 1052 50-40-5 T870 Service Manual

434 of 1052 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].

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.

435 of 1052 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.

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].

436 of 1052 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.

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 22,2 mm (0.875 in) punch (Item 1) [Figure 50-41-
Tach pivot pin retaining bolt (both sides). 9] and a hammer, drive the pivot pin out of the lift arm
and Bob-Tach (both sides).

Remove the Bob-Tach from the loader.

NOTE: MEL1685 - Pivot Point Tapered Reamer is

available to ream out tapered bore if
necessary.

437 of 1052 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).
35,3 mm
Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ft-
(1.39 in)
lb) torque.

Remove the cylinder from the lever pivots.

Figure 50-41-11

P127544

1 Installation: Tighten the lever mounting nut until the

spring is compressed to 35,3 mm (1.39 in) [Figure 50-
41-13].

P-85664

Remove the lever mounting nut (Item 1) [Figure 50-41-

11].

438 of 1052 50-41-4 T870 Service Manual

BOB-TACH (POWER) (CONT'D) Earlier Design

Lever And Wedge Disassembly And Assembly Figure 50-41-16

(Cont'd)

Figure 50-41-14 4
3

1 1

2
P19287

P-85666 If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) are damaged, put the assembly in a
vise. Loosen and remove the bolt (Item 1) [Figure 50-41-
Use a punch and hammer to remove the roll pin (Item 1) 16]. Replace the worn or damaged parts as needed.
[Figure 50-41-14] from the Bob-Tach wedge and spring
clevis. Assembly: Clean the threads and apply Loctite® 242 to
the bolt (Item 1) [Figure 50-41-16], tighten to 125 - 135
Remove the spring clevis assembly (Item 2) [Figure 50- N•m (90 - 100 ft-lb) torque.
41-14].
Later Design
Figure 50-41-15
Figure 50-41-17

4
3
2
1

P-85667

P121303

Remove the wedge (Item 1) [Figure 50-41-15] out the

bottom of the Bob-Tach. If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) are damaged, put the assembly in a
Always replace bent or broken wedges. vise. Loosen and remove the bolt (Item 1) [Figure 50-41-
17]. Replace the worn or damaged parts as needed.

Assembly: Clean the threads and apply Loctite® 242 to

the bolt (Item 1) [Figure 50-41-17], tighten to 48 - 54
N•m (35 - 40 ft-lb) torque.

439 of 1052 50-41-5 T870 Service Manual

BOB-TACH (POWER) (CONT'D)

Pivot Pin Bushing And Seal Removal And Installation

Figure 50-41-18

2 1

P-85669

Remove the Power Bob-Tach. (See Removal And

Installation on Page 50-41-1.)

Use a seal pick to remove seal (Item 1) [Figure 50-41-

18] from the Bob-Tach.

Remove and replace bushing (Item 2) [Figure 50-41-18]

with a driver tool and hammer.

Figure 50-41-19

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 50-41-19].

440 of 1052 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
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.

441 of 1052 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
Install a sling and chain hoist on the lift arm link [Figure
50-50-5].

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).

442 of 1052 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

P-90610

1 2
Remove the lift arm link pivot pin (Item 1) [Figure 50-50-
9] (both sides).
P115833
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 nut (Item 3) [Figure 50-

50-10].

443 of 1052 50-50-3 T870 Service Manual

LIFT ARMS (CONT’D) Figure 50-50-13

Removal And Installation (Cont’d)

Figure 50-50-11
1

1 P115835

At the left side upright remove both of the auxiliary hose

P100263 mounting clamp nut (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].

NOTE: Mark the hoses for proper installation.

Figure 50-50-12
1

P115836

Disconnect the electrical controls harness (Item 1)

[Figure 50-50-14]. (If equipped.)

P115834

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.

444 of 1052 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

P100226A and connect to a chain hoist.

Figure 50-50-18
Remove the retaining bolt, nut and washers (Item 1)
[Figure 50-50-15] from the pin on the rod end of the lift
cylinder (both 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
removed. 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).

445 of 1052 50-50-5 T870 Service Manual

LIFT ARMS (CONT’D) Figure 50-50-21

Removal And Installation (Cont’d)

Figure 50-50-19

1 2

P100713

Remove the grease fitting (Item 1) from the lift arm pivot
P109395 pin and then with a slide hammer remove the lift arm
pivot pin (Item 2) [Figure 50-50-21] (both sides).

Position the front sling in the middle of the Bob-Tach as Remove the lift arms from the loader.
shown in (Item 1) [Figure 50-50-19].

Support the lift arms with the chain hoist.

Figure 50-50-20

2
1

P100714

Remove the retaining ring (Item 1) and the washer (Item

2) [Figure 50-50-20] from the lift arm pivot pin (both
sides).

446 of 1052 50-50-6 T870 Service Manual

REAR GRILLE Installing

Removing Figure 50-60-3

Stop the engine.

Figure 50-60-1

1 P109931

Insert the front tab of the two side covers into the slots in
P121151A
the loader frame and lower [Figure 50-60-3]. (Left side
shown.)

Remove the clamping knob (Item 1). Lift using the handle Figure 50-60-4
(Item 2) [Figure 50-60-1] and pull the rear grille
backward to remove from the loader.

Figure 50-60-2

P109722

Insert the edge of the rear grille under the loader frame
P121215A
and slide rear grille in while lowering [Figure 50-60-4].

Install the clamping knob (Item 1) [Figure 50-60-1].

Lift and remove the two side covers (Item 1) [Figure 50-
60-2].

447 of 1052 50-60-1 T870 Service Manual

REAR GRILLE (CONT’D)

Shield Removal And Installation

Figure 50-60-5

1 1
2

P115758

Remove the two bolts (Item 1) and remove the shield

(Item 2) [Figure 50-60-5].

448 of 1052 50-60-2 T870 Service Manual

REAR DOOR (TAILGATE) Figure 50-70-3

Removal And Installation

1
Figure 50-70-1

2
2
3

P115841

Remove the top and bottom door hinge mounting bolts

P115837 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].

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

P115840

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.

449 of 1052 50-70-1 T870 Service Manual

REAR DOOR (TAILGATE) (CONT’D) Striker (Adjusting)

Striker Removal And Installation

Figure 50-70-4 WARNING

AVOID INJURY OR DEATH
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
1 W-2012-0497

Figure 50-70-6

1
1

P115861

Remove the two striker mount bolts (Item 1) [Figure 50-

70-4].
1
Remove the striker assembly from the loader.

Striker Disassembly And Assembly P115861

Figure 50-70-5
Loosen the striker assembly mount bolts (Item 1) [Figure
50-70-6].
3 2
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
4
the center of the mounting slots.
1
Close the rear door. (This will align the striker assembly
to the correct position.)

Open the door.

P109091
Tighten both striker mount bolts (Item 1) [Figure 50-70-
6] to 125 - 135 N•m (90 - 100 ft-lb) torque.
Remove the locknut (Item 1) [Figure 50-70-5].
Close the rear door.
Remove the roller (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.

450 of 1052 50-70-2 T870 Service Manual

REAR DOOR (TAILGATE) (CONT’D) Figure 50-70-9

Latch Removal And Installation

Figure 50-70-7
1

2
1

P109094

Remove the door handle (Item 1) [Figure 50-70-9] from

P109092 the rear door.

Check the parts for wear and replace as needed.

Remove the bolt (Item 1) and nut (Item 2) [Figure 50-70-
7] from the latch.

Installation: Tighten the bolt (Item 1) and nut (Item 2) to

34 - 38 N•m (25 - 28 ft-lb) torque.

Figure 50-70-8

P109093

Remove the spring (Item 1) [Figure 50-70-8] from the

latch.

451 of 1052 50-70-3 T870 Service Manual

REAR DOOR (TAILGATE) (CONT’D) Figure 50-70-12

Tailgate Fan Removal And Installation

2
Figure 50-70-10

1
2
P121146

Remove the twelve bolts (Item 1) and tailgate protector

P121144 (Item 2) [Figure 50-70-12] from the tailgate.

Installation: Tighten the bolt (Item 1) [Figure 50-70-12]

Cut the tie strap (Item 1) and disconnect the wire and nut (Item 1) [Figure 50-70-11] to 50 - 54 N•m (37 -
connector (Item 2) [Figure 50-70-10] (both sides). 40 ft-lb).

Figure 50-70-11 Figure 50-70-13

1 1

1
2

1 1

P121145 P121147

Remove the twelve nuts (Item 1) [Figure 50-70-11]. Remove the nuts and bolts (Item 1) and the tailgate fan
(Item 2) [Figure 50-70-13] from the rear door.

Installation: Tighten the bolts and nuts to 12,2 - 13,5

N•m (9 - 10 ft-lb) torque.

452 of 1052 50-70-4 T870 Service Manual

FUEL TANK Figure 50-80-2

Removal And Installation

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

P106481
Lift and block the loader. (See Procedure on Page 10-10-
1.)
Remove the two mounting bolts (Item 1) and remove the
Remove the engine / hydrostatic pump assembly from bracket (Item 2) [Figure 50-80-2].
the loader. (See Engine Removal And Installation on
Page 70-10-15.) Figure 50-80-3

Drain the fuel into a container.

Figure 50-80-1

P106482

1
Remove the bolts (Item 1) [Figure 50-80-3] from the
P106480 battery hold-down plate.

Remove the hold-down plate from the loader.

Disconnect the two fuel lines (Item 1) [Figure 50-80-1].

NOTE: Mark the fuel lines for correct installation.

Disconnect the wire harness connector (Item 2) [Figure

50-80-1] from the fuel level sender.

453 of 1052 50-80-1 T870 Service Manual

FUEL TANK (CONT’D) Fuel Level Sender Removal And Installation

Removal And Installation (Cont'd) Lift and block the loader. (See Procedure on Page 10-10-
1.)
Figure 50-80-4
Remove the engine / hydrostatic pump assembly from
the loader. (See Engine Removal And Installation on
Page 70-10-15.)

Figure 50-80-5

1 1

P115945

Remove the bolt (Item 1) and bracket (Item 2) [Figure

50-80-4].
P106480
Lift the fuel tank and remove it from the loader frame.

NOTE: When installing the fuel tank, avoid striking Disconnect the wire harness connector (Item 1) [Figure
the tank with heavy objects to prevent 50-80-5] from the fuel level sender.
damage.
Remove the fuel level sender.

Figure 50-80-6

P-85716

Inspect the fuel level sender and replace if worn or

damaged [Figure 50-80-6].

454 of 1052 50-80-2 T870 Service Manual

FUEL TANK (CONT’D) Figure 50-80-9

Fuel Fill Screen Removal And Installation

NOTE: The fuel filter is removed for photo clarity.

1
Figure 50-80-7

P115821

Reposition the clamp (Item 1) and remove the fuel fill

hose (Item 2) [Figure 50-80-9].

P115820
Figure 50-80-10

Remove the two bolts (Item 1) [Figure 50-80-7].

Figure 50-80-8

P115842

Remove the fuel fill screen (Item 1) [Figure 50-80-10].

P115828 Inspect and replace as needed.

Remove the hose / clamp (Item 1) [Figure 50-80-8] from

the filler neck.

455 of 1052 50-80-3 T870 Service Manual

456 of 1052 50-80-4 T870 Service Manual
FUEL TANK (AUXILIARY) Drain the fuel into a container.

Removal And Installation Figure 50-81-1

Raise the lift arms and install an approved lift arm

support device. (See Installing on Page 10-20-2.)

Lift and block the loader. (See Procedure on Page 10-10-

1.)

1
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
P-90983
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Disconnect and plug the two fuel hoses (Item 1) [Figure
50-81-1].
Raise the operator cab. (See Raising on Page 10-30-1.)
Figure 50-81-2

DANGER 1

P-90328

AVOID DEATH
P-90984
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop. Remove the four bolts (Item 1) and the bracket (Item 2)
• Keep out of this area when lift arms are raised [Figure 50-81-2].
unless supported by an approved lift arm
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) (SCPA) on Page 50-121-1.)

Remove the floor pan. (See Floor Pan Removal And

Installation on Page 50-90-4.)

457 of 1052 50-81-1 T870 Service Manual

FUEL TANK (AUXILIARY) (CONT’D)

Removal And Installation (Cont'd)

Figure 50-81-3

P-90985

Remove the auxiliary fuel tank (Item 1) by lifting the rear

of the tank upwards [Figure 50-81-3].

458 of 1052 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 operator’s feet.

Pedal Removal And Installation

WARNING P107840

Never work on a machine with the lift arms up unless Remove the bolt and nut (Item 1) [Figure 50-90-1] 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

Figure 50-90-2
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)

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

DANGER
1

P107841

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

459 of 1052 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-
90-5].
Remove the bolt and nut (Item 1) [Figure 50-90-3] to
disconnect the lift pedal linkage from the crossbar. 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.

460 of 1052 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

1 so full movement of the pedal can be reached easily
while properly sitting in the loader seat.
2 Figure 50-90-9

P107840
1

Remove the bolt and nut (Item 1) [Figure 50-90-7] from

the pedal linkage.

Remove the linkage (Item 2) [Figure 50-90-7]. P-85676

Figure 50-90-8 Loosen the two mounting bolts (Item 1) [Figure 50-90-9]
from the pedal mounting bracket.

1 Figure 50-90-10

2
1

2
P-85675A

Remove the bolt and nut (Item 1) [Figure 50-90-8] from P107840

the pedal linkage.

Loosen the bolt and nut (Item 1) [Figure 50-90-10] on
Remove the linkage (Item 2) [Figure 50-90-8]. the pedal linkage.

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.

461 of 1052 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) (SCPA) on Page 50-121-1.)

Figure 50-90-11

1
1

P-85859 P-85860

Figure 50-90-12

1 1

P107844

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].

462 of 1052 50-90-4 T870 Service Manual

CONTROL PANEL (SJC) Figure 50-100-1

Description 1

The control panel is connected to the lower main frame

and wraps around the operator seat. There are no
mechanical linkages connecting to the hydrostatic pumps
or the control valve.

Removal And Installation

WARNING
P-85879A
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 Remove the three mount bolts (Item 1) [Figure 50-100-1]
fall or move and cause injury or death. that secure the controller.
W-2017-0286

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 1 3 1
can cause lift arms to drop.
• Keep out of this area when lift arms are raised P-85881A
unless supported by an approved lift arm
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

(Item 2) [Figure 50-100-2].
WARNING 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

Raise the lift arms and install an approved lift arm

support device. (See Installing on Page 10-20-2.)

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

463 of 1052 50-100-1 T870 Service Manual

464 of 1052 50-100-2 T870 Service Manual
CONTROL PANEL (SCPA) Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
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 Figure 50-101-1
mechanical linkages connected to the control valve.

Removal And Installation

WARNING 1

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

P115851

DANGER Remove the three mount bolts (Item 1) [Figure 50-101-1]

that secure the controller.

Figure 50-101-2

1 1
1
1
P-90328
2
AVOID DEATH 1
• 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 1 1
unless supported by an approved lift arm 3
support. Replace if damaged.
D-1009-0409 P115862

Remove the 10 panel mount bolts (Item 1) [Figure 50-

101-2].

WARNING Remove the lift arm bypass knob and rubber washer
(Item 2) [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 Remove the control panel (Item 3) [Figure 50-101-2].
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

465 of 1052 50-101-1 T870 Service Manual

466 of 1052 50-101-2 T870 Service Manual
CONTROL HANDLE / LEVER (SJC)

Description

The operator’s 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.

467 of 1052 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 10-20-2.) 1

Figure 50-110-1

P-85891

1 Disconnect the joystick connector (Item 1) [Figure 50-

110-3] from the harness connector.

P-85890

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.

Installation: Tighten the four screws to 4,0 - 4,5 N•m (35

- 40 in-lb) torque.

468 of 1052 50-110-2 T870 Service Manual

CONTROL HANDLE / LEVER (SCPA)

Description

The operator’s 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.

469 of 1052 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 10-20-2.) 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

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.

Installation: Tighten the four screws to 4,0 - 4,5 N•m (35

- 40 in-lb) torque.

470 of 1052 50-111-2 T870 Service Manual

ACCESS PANEL (INSIDE) (SJC) Removal And Installation (Right)

Removal And Installation (Left) Figure 50-120-3

Figure 50-120-1

2 2
1

P106589

P100731
Remove the two mounting nuts (Item 1), and remove the
footrest (Item 2) [Figure 50-120-3].
Remove the two nuts (Item 1) and remove the footrest
(Item 2) [Figure 50-120-1]. Figure 50-120-4

Figure 50-120-2

1 1
2

P106590
2
P100732
NOTE: Mark the location of the foot pedal before
removal for correct assembly.
Remove the four bolts (Item 1), and remove the access
panel (Item 2) [Figure 50-120-2]. Loosen the clamping bolt (Item 1) and remove the engine
speed control foot pedal (Item 2) [Figure 50-120-4].

Calibrate the foot throttle during installation. (See Foot

Throttle Calibration on Page 70-21-4.)

471 of 1052 50-120-1 T870 Service Manual

ACCESS PANEL (INSIDE) (SJC) (CONT’D)

Removal And Installation (Right) (Cont’d)

Figure 50-120-5

2
1
1

P106591

Remove the four bolts (Item 1) and remove the right

inside access panel (Item 2) [Figure 50-120-5].

472 of 1052 50-120-2 T870 Service Manual

ACCESS PANEL (INSIDE) (SCPA) 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 50-121-2

Figure 50-121-1

2
P107842

P107843
Remove the four mounting bolts (Item 1) and remove the
right access panel (Item 2) [Figure 50-121-2].
Remove the four mounting bolts (Item 1), and remove the
left access panel (Item 2) [Figure 50-121-1]. Remove the right access panel from the loader.

Remove the left access panel from the loader.

473 of 1052 50-121-1 T870 Service Manual

474 of 1052 50-121-2 T870 Service Manual
WINDOW (REAR) Removal (Rubber Cord)

Rear Window Identification

Figure 50-130-1 WARNING

Latches Rubber Cord
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
2 • When fluids are under pressure.
• Flying debris or loose material is present.
1 • Engine is running.
• Tools are being used.
P-85309B P-64994G W-2019-0907

Figure 50-130-2

There are two different procedures for removing the rear

window from your machine:

1. This window is equipped with latches (Item1) [Figure

50-130-1].

2. This window is equipped with a rubber cord and tag

(Item 2) [Figure 50-130-1].

P-64994F

Pull on the tag on the top of the rear window to remove

the rubber cord [Figure 50-130-2].

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

NOTE: If rear window is broken, remove all glass

fragments from the rubber molding before
installing a new window.

475 of 1052 50-130-1 T870 Service Manual

WINDOW (REAR) (CONT’D) Figure 50-130-5

Installation (Rubber Cord)

Clean the area before installing the rear window

assembly.

Figure 50-130-3

P109581

Install the rear window assembly from the outside of the

operator cab into the window frame.

Install a lower corner of the rear window assembly into

1
P109560 the corner of the window frame (Item 1) [Figure 50-130-
5].

Install the rubber molding (Item 1) [Figure 50-130-3] Work the window assembly downward until the window is
around the edge of the rear window. fully seated in the lower portion of the window frame.

Figure 50-130-4 Figure 50-130-6

P-85228 P109582

Apply liquid soap to the rubber molding (Item 1) [Figure Apply light pressure to the outside of the widow assembly
50-130-4] to make installation easier. holding it tight up against the window frame.

NOTE: Install the window assembly with the narrow Use a multipurpose tool (Item 1) [Figure 50-130-6] under
edge (Item 2) [Figure 50-130-4] toward the the molding lip to guide the window assembly into the
inside of the loader. window frame.

NOTE: Tapping the window with a rubber hammer

will help seat the window assembly in the
window frame.

476 of 1052 50-130-2 T870 Service Manual

WINDOW (REAR) (CONT’D)

Installation (Rubber Cord) (Cont’d)

Figure 50-130-7

P109583A

Apply liquid soap on the rubber cord to make installation

easier. Install the rubber cord (Item 1) [Figure 50-130-7]
with the safety tag into the molding on the inside of the
operator cab.

NOTE: Verify the safety tag is located in the top

center of the window.

477 of 1052 50-130-3 T870 Service Manual

WINDOW (REAR) (CONT’D) Disassembly And Assembly (Latches)

Removal And Installation (Latches) Figure 50-130-9

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 50-130-8

Remove the screw (Item 1) from the latch [Figure 50-

130-9].

Installation: Tighten the screw (Item 1) [Figure 50-130-

9] to 21 - 23 N•m (180 - 200 in-lb) torque.
1 1
Figure 50-130-10

7
6
1

P-85706

5
Remove the rear window assembly by turning the two
latches (Item 1) [Figure 50-130-8] 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 50-130-10].
assembly.
1. Latch
Reverse the procedure to install the rear window.
2. Spacer
3. Bushing
4. Washer
5. Screw
6. Rear Window
7. Seal

478 of 1052 50-130-4 T870 Service Manual

WINDOW (TOP) Figure 50-131-3

Removal And Installation

Figure 50-131-1

1 1

P107298A
1 1

To help control the amount of adhesive compression

P-85808 during installation and maintain the ideal adhesive
thickness to maintain the bond, bushing spacers (Item 1)
[Figure 50-131-3] have been added between the window
From inside the operator cab, remove the four nuts (Item and cab.
1) [Figure 50-131-1].
Figure 50-131-4
Figure 50-131-2

1 1
1 1

2
P-85807
P-85807

Align the window and cab holes prior to placing window.

Remove the bolts (Item 1). Separate the window Install the bolts (Item 1) [Figure 50-131-4] through the
adhesive (Item 2) [Figure 50-131-2] from the cab. window grommets, bushing spacers and cab.

Remove the existing adhesive from the mounting

surfaces.

Prime and paint any bare metal or scratches.

Clean the metal surfaces with general purpose adhesive

cleaner. Clean the glass surface with glass cleaner.

Approximately 10 mm (0.38 in) from the edge of the

window, apply a consistent and continuous 10 mm (0.38
in) bead of adhesive to the window.

479 of 1052 50-131-1 T870 Service Manual

WINDOW (TOP) (CONT’D)

Removal And Installation (Cont’d)

Figure 50-131-5

1 1

1 1

P-85808

From inside the operator cab, install the four nuts (Item 1)
[Figure 50-131-5].

Tighten the nuts (Item 1) [Figure 50-131-5] to 9 - 10 N•m

(80 - 90 in-lb) torque.

NOTE: Allow two hours of cure time before exposing

to direct sunlight or significant temperature or
humidity changes.

480 of 1052 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 10-20-2.)
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.

Figure 50-132-2 Remove the window assembly.

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.

481 of 1052 50-132-1 T870 Service Manual

482 of 1052 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

P-85781A 1
2

Open the cab door.

NOTE: Later models route the washer fluid hose

differently and will not require this step.

Disconnect electrical connector (Item 2) and washer fluid

hose (Item 1) (if equipped) [Figure 50-140-1].

Figure 50-140-2

2
3

2 1

1 P-85837

Remove the four bolts and nuts (Item 2) [Figure 50-140-

4] from the cab.
P-85588A P-85589A

Remove the hinges (Item 1) [Figure 50-140-4] from the

Rotate and pull the clip (Item 1) out of the gas spring cab.
socket. Pull the gas spring socket (Item 3) straight off the
ball stud fitting (Item 2) [Figure 50-140-2]. 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.

483 of 1052 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].
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].

484 of 1052 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].

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.

485 of 1052 50-140-3 T870 Service Manual

CAB DOOR (CONT’D) Checking Operation

Adjusting Figure 50-140-15

Figure 50-140-13

2
1
1

P-85413F

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.
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.

P107832

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.)

486 of 1052 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

Adjustable armrests (Item 1) [Figure 50-150-1].

487 of 1052 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.

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.

488 of 1052 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

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].

489 of 1052 50-150-3 T870 Service Manual

ARMREST (CONT’D) Figure 50-150-11

Disassembly And Assembly (Cont’d)

Figure 50-150-9

3 1 1

2 2

1 P-90844

Remove the two nuts (Item 1) and the slide rail (Item 2)
P100825 [Figure 50-150-11] from the armrest mount.

Repeat for the other side.

Figure 50-150-10

7
3
6
5 2
4 1

P100824

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), washer (Item 5), plastic

washer (Item 6) and the bolt (Item 7) [Figure 50-150-10].

Installation: Tighten the nut to 21 - 23 N•m (180 - 200 in-

lb) torque.

490 of 1052 50-150-4 T870 Service Manual

LEFT SIDE LOWER PANEL Figure 50-160-3

Removal And Installation

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

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].

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 50- 1
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.

491 of 1052 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].

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.

492 of 1052 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

P-90865

NOTE: If the three clips (Item 1) [Figure 50-160-11] are

removed the cup holder will need to be
replaced.

493 of 1052 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.

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.

494 of 1052 50-160-4 T870 Service Manual

RIGHT SIDE LOWER PANEL Figure 50-170-3

Removal And Installation 2

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

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

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.

495 of 1052 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.
NOTE: The power port lock washer must be replaced
NOTE: Pull the right side lower panel away from the with 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.

496 of 1052 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.

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.

497 of 1052 50-170-3 T870 Service Manual

498 of 1052 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).
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 groove 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).

499 of 1052 50-180-1 T870 Service Manual

500 of 1052 50-180-2 T870 Service Manual
FAN DUCT PANELS Figure 50-190-2

Removal And Installation

Raise the lift arms and install an approved lift arm 2

support device. (See Installing on Page 10-20-2.) 1

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

3
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.)

Remove the fan duct. (See Lower Fan Duct Removal And
Installation on Page 70-60-4.)

P115931

IMPORTANT Remove the bolt (Item 1) and p-clip (Item 2) from the
hose (Item 3) [Figure 50-190-2]. (Both sides.)
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all Figure 50-190-3
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
Figure 50-190-1

1
2
1
1
P121205

Remove the three bolts (Item 1) and remove the plate

(Item 2) [Figure 50-190-3].

P115778A

Remove the fan motor inlet hose (Item 1) and outlet hose
(Item 2) [Figure 50-190-1].

501 of 1052 50-190-1 T870 Service Manual

FAN DUCT PANELS (CONT’D)

Removal And Installation (Cont’d)

Figure 50-190-4

2
1

P121206

Remove the two bolts (Item 1) [Figure 50-190-4] and

remove the plate (Item 2).

502 of 1052 50-190-2 T870 Service Manual

 ELECTRICAL SYSTEM AND ANALYSIS

ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Deluxe Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
SCPA Mainframe Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
SJC Mainframe Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Engine Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-10
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-15

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
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5

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
Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-10
Left Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Right Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Key Switch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-13
Alarm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-13
Left Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-14
Right Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-14

503 of 1052 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 CONTOLERS (GATEWAY AND AUXILLIARY) . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-4

BOBCAT CONTROLLER (SJC) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1
Connector Identification (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-2
Removal And Installation (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-4
Connector Identification (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-6
Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-9

BOBCAT CONTROLLER (SCPA) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-1
Connector Identification (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-2
Removal And Installation (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-4
Connector Identification (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-6
Removal And Installation (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-9

DOSING CONTROL UNIT (DCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Removal And installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

ENGINE CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-3

DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2

504 of 1052 60-02 T870 Service Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Inspecting The BICS™ (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Inspecting Deactivation Of The Auxiliary Hydraulics System 
(Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Inspecting The Lift Arm Bypass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
Inspecting Deactivation Of Lift And Tilt Functions (SJC) . . . . . . . . . . . . . . . . . . . . 60-110-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-3

SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3
Bobcat Interlock Control System (BICS™) Circuit Test . . . . . . . . . . . . . . . . . . . . . 60-120-6

TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-2
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-3

ELECTRICAL / HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-3
Identification Chart ACD Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-4
Identification Chart ACD Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-5
Identification Chart ACD Group 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-6

ELECTRICAL / HYDRAULIC CONTROLS (SCPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-2
Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-3
Identification Chart ACD Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-4
Identification Chart ACD Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-5
Identification Chart ACD Group 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-6

SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Lift And Tilt Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-6
Hydrostatic Pump Calibration (SCPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-11

505 of 1052 60-03 T870 Service Manual

STEERING DRIFT COMPENSATION (OPERATOR MODE) . . . . . . . . . . . . . . . . . . . . 60-170-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1

STEERING DRIFT COMPENSATION (SERVICE MODE) . . . . . . . . . . . . . . . . . . . . . . 60-171-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-171-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-171-1

CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

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

FRONT HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-2
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-3

ENGINE COMPARTMENT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 60-230-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-230-1

506 of 1052 60-04 T870 Service Manual

 CONNECTOR ASSIGNMENTS
NUM NUM NUM NUM
CONN DESCRIPTION OF SHEET CONN DESCRIPTION OF SHEET CONN DESCRIPTION OF SHEET CONN DESCRIPTION OF SHEET
PINS PINS PINS PINS
C100 WATER IN FUEL SENDER 2 9 C277 AIR RIDE SEAT 6 17 C480 LEFT PANEL(GRAY) 12 12 J5 DRIVE CONTROLLER 48 4,5,6,7,14
C103 TAILGATE HARNESS 8 6,14,15,17 C278 RIGHT SPEAKER 2 17 C482 SEATBAR SENSOR 3 13 J7A ENG ECU CONTROLLER (BCT) 58 5,6,8,9
C104 TAILGATE FANS 4 9 C279 LEFT SPEAKER 2 17 C483 TEMP CONTROL SWITCH 3 16 SW1 BRAKE SWITCH 6 12
C105 HYD CHARGE PRESSURE 3 11 C308 BRAKE SOLENOID 2 11 C486 AC COMPRESSOR 2 16 SW2 BEACON SWITCH 6 17
SENSOR
C108 HYD TEMPERATURE SENDER 2 11 C350 AC EVAPORATOR SWITCH 2 16 C489 MFR ACCESSORY 2 5,6 SW3 HAZARD SWITCH 6 17
C111 MFR-BCT ENG HARN CONN 3 9 C355 FUEL HARNESS 6 9,17 C497 SJC HORN/BLINKER 3 17 SW4 HAND/FOOT, H/ISO SWITCH 6 14
C112 HYD OIL FILTER SWITCH 2 11 C405 AIR FILTER SWITCH 2 9 C499 PTOL 4 12 SW5 POWER BOBTACH SWITCH 6 17
C113 RIGHT TAILGATE FAN CONN 2 9 C406 FUEL SENDER 2 9 C500 RH KEY SWITCH 6 12 SW6 BUCKET POSITION SWITCH 6 17
C114 HAND THROTTLE 6 9 C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,12,13, C501 A22 PUMP HARN CONN 8 14 SW9 TRAVEL CONTROL SWITCH 6 12
15,17
C115 FOOT THROTTLE 6 9 C411 LEFT HANDLE 5 WAY 5 17 C503 RH DLX PANEL 6 7,12 SW10 BLOWER SWITCH 5 16
C412 LEFT HANDLE 2 WAY 2 17 C536 A22 PUMP HARN - R SWASH 4 14 SW11 AC SWITCH 3 16
C118 ENG-CROSSOVER 4 9 C415 HIGH FLOW SOLENOID 2 17 C537 A22 PUMP HARN - L SWASH 4 14 SW12 DPF SWITCH 10 12
C119 LEFT TAILGATE FAN CONN 2 9 C418 FRONT ROD 2 11 C542 LEFT SWASH PLATE 3 14 T1 BATT GROUND 1 6
C120 ENGINE TEMP SENSOR 2 9 C419 FRONT BASE 2 11 C543 RIGHT SWASH PLATE 3 14 T2 BUZZER GROUND 1 12
C121 DOSING CONTROL UNIT 94 8,10 C420 HYD LOCK 2 11 C544 LEFT FORWARD DRIVE 2 14 T3 FLASHER 2 17
C122 SUPPLY MODULE 12 10 C545 LEFT REVERSE DRIVE 2 14 T4 MEGAFUSE 1 4
C123 HOSE 1 HEATER 2 10 C546 RIGHT FORWARD DRIVE 2 14 T6 BATT GROUND 1 6
C124 HOSE 2 HEATER 2 10 C423 BUCKET POSITION 2 17 C547 RIGHT REVERSE DRIVE 2 14 T8 BATT GROUND 1 6
C125 HOSE 3 HEATER 2 10 C425 BRAKE SOLENOID 3 11 C602 LEFT REAR TAIL LIGHT 2 15 T10 ENGINE SYSTEM GROUND 1 6
C126 HORN 2 17 C426 CAN (Remote Start Tool, ACD) 7 7 C603 RIGHT REAR TAIL LIGHT 2 15 T13 BUZZER POWER 1 12
C129 CAB ACCESSORY 3 13 C427 TILT ACTUATOR 8 14 C606 POWER BOBTACH OPEN 2 17 T14 PRE HEATER 1 9
C155 TANK HEATING VALVE 4 10 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,9,13,17 C607 POWER BOBTACH CLOSE 2 17 T15 RIGHT REAR WORK LIGHT(+) 1 15
C156 REDUCTION AGENT METERING 2 10 C429 LIFT ACTUATOR 8 14 HVAC DUCT FAN 2 T16 RIGHT REAR WORK LIGHT(-) 1 15
C610 16
VALVE
C157 CATALYST TEMP SCR INLET 2 10 C434-1 LEFT FRONT LIGHT (37W) 2 15 C611 BLOWER MOTOR 4 16 T17 LEFT REAR WORK LIGHT (+) 1 15
C158 CATALYST TEMP SCR OUTLET 2 10 C434-2 LEFT FRONT LIGHT (50W) 2 15 C630 THERMOSTAT 3 16 T18 LEFT REAR WORK LIGHT (-) 1 15
C159 ENVIRONMENTAL TEMP 2 10 C435-1 RIGHT FRONT LIGHT (37W) 2 15 C635 HEATER VALVE 6 16 T19 BACKUP ALARM 1 14
C160 CATALYST TEMP DOC INLET 2 10 C435-2 RIGHT FRONT LIGHT (50W) 2 15 C667 DOOR HARNESS 6 13 T20 BACKUP ALARM (GND) 1 14
C161 DEF TANK 4 8 C438 CAB-MFR HARN CONN(DK GRY) 14 13,14,15,16, C670 EXTERIOR BEACON HARNESS 6 17 T26 FUSE 150 AMP 1 9
17
C163 NOx PRETREATMENT 5 8 C441 TWO SPEED SOLENOID 2 17 C676 RADIO 6 17
T27 PRE HEATER CONTACTOR PWR 1 9
C164 NOx POST TREATMENT 5 8 C446 HYDRAULIC FAN SOLENOID 2 11 FRC1 FUSE RELAY CENTER 112 4,5,9,15,16 T29 BATTERY 1 9

C169 ENGINE CAN DIAGNOSTIC 6 8 C449 LEFT JOYSTICK(CAB HARN) 4 7,14 J1A GATEWAY CONTROLLER 34 5,9,11,12,15
T32 ECU CASE GND 1 6
,16,17
C171 INLINE FAN FUSE LEFT 2 9 C450 RIGHT JOYSTICK(CAB HARN) 4 7,14 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,11
T31 PREHEATER 1 9
12,14,13,17
C172 INLINE FAN FUSE RIGHT 2 9 C459 LEFT HANDLE 4 14 J2A AUX CONTROLLER 34 11,17 T33 DCU CASE GND 1 10

C212 POWER SOCKET 2 13 C460 RIGHT HANDLE 4 14 J2B AUX CONTROLLER 26 4,5,6,7,11, 1 13
T37 DOME LIGHT +
17
C252 WASHER ADAPTER INTMD 2 13 C474 BRAKE (ROAD KIT) 1 14 J3A ACS CONTROLLER 8 5,6,7,14 T38 DOME LIGHT - 1 13
C253 WASHER PUMP 2 13 C479 LEFT PANEL(BLACK) 12 7,12 J3B ACS CONTROLLER 10 14,17 T42 PREHEATER FDBK 1 9
J3C ACS CONTROLLER 10 4,6,14

WIRING SCHEMATIC
(SJC MACHINE) Printable Version Click Here
T870 (S/N ASWT11001 - ASWT11577)
(S/N B3BZ11001 - B3BZ11129)
Sheet 1 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222672 (B)
507 of 1052
 J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER)
PIN FUNCTION PIN FUNCTION
PIN FUNCTION PIN FUNCTION A-1 FRONT AUX (F) RETURN (BASE) B-1
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS
A-2 B-2 UNSW BATT
A-2 B-2 UNSW BATT
A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-3 HVAC RELAY - B B-3 UNSW BATT
A-4 RIGHT BLINKER RELAY B-4
A-4 SWITCHED PWR OUT RELAY - A B-4 ENGINE RUN SIGNAL
A-5 HORN RELAY B-5
A-5 FRONT LIGHT RELAY - J B-5
A-6 B-6
A-6 B-6 TRACTION LOCK HOLD
A-7 B-7
A-7 STARTER RELAY - M B-7
A-8 B-8 CAN LO 1
A-8 B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 TAILGATE FANS OUT RELAY - C B-9 CAN HI 1
A-10 B-10
A-10 B-10 HAND THROTTLE
A-11 B-11
A-11 AC SENSE B-11 SEAT BAR
A-12 B-12
A-12 LEFT FAN FDBK RELAY - C B-12 FUEL LEVEL
A-13 B-13 FRONT AUX (F) (BASE)
A-13 B-13 BICS HYD LOCK HOLD
A-14 B-14 CAN HI 2
A-14 B-14 CAN HI 2
A-15 B-15 GROUND
A-15 B-15 GROUND P1
A-16 B-16 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2
A-17 B-17
A-17 REAR LIGHT RELAY - E B-17 GROUND P3, SENSOR
A-18 FRONT AUX (M) RETURN (ROD) B-18
A-18 HYD FAN RETURN B-18 ENGINE TEMP SENSOR
A-19 B-19 FRONT AUX (M) (ROD)
A-19 PTOL LED B-19 HYD FAN OUTPUT
A-20 B-20 CAN LO 2
A-20 PTOL SWITCH B-20 CAN LO 2
A-21 B-21
A-21 SWITCHED PWR FDBK RELAY - A B-21 REMOTE RUN KEY
A-22 B-22 SWITCHED PWR
A-22 STATER FDBK RELAY - M B-22 RUN/ENTER
A-23 B-23
A-23 B-23 SENSOR SUPPLY 8V
A-24 B-24
A-24 START ENGINE B-24 SENSOR SUPPLY 5V
A-25 B-25
A-25 RIGHT FAN FDBK RELAY - C B-25
A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-26 TWO SPEED RETURN B-26 TWO SPEED COIL
A-27
A-27
A-28
A-28 REAR LIGHT FDBK RELAY - E
A-29
A-29
A-30
A-30 HVAC FDBK RELAY - B
A-31
A-31 FRONT LIGHTS FDBK RELAY - K
A-32
A-32 HYD OIL TEMP (8 VOLT)
A-33
A-33 FOOT THROTTLE
A-34
A-34 HYD OIL FILTER SW1
HARNESS PART NUMBER
ACS CONTROLLER EXLF MFR SJC 7267011
CONNECTOR J3A CONNECTOR J3B CONNECTOR J3C DLX CAB 7253375
PIN FUNCTION PIN FUNCTION PIN FUNCTION DLX FUEL 7266824
A +5V TO SENSORS A A TILT MOTOR 1 BCT ENG 7242470
B SWITCHED POWER B B UNSWITCHED POWER TAILGATE DOM 7267103
C C C UNSWITCHED POWER SUSP JSTK 7163706
D CAN HI D D LIFT MOTOR 2 BRAKE ADAPTER 7234968
E CAN LO E TILT ACTUATOR FEEDBACK E WHL 2 SPD ADP 7159366
F F F LIFT MOTOR 1 TRACK 2 SPD 7214627
G GROUND G G
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND Printable Version Click Here
J
K
J
K
GROUND
TILT MOTOR 2
WIRING SCHEMATIC
(SJC MACHINE)
T870 (S/N ASWT11001 - ASWT11577)
(S/N B3BZ11001 - B3BZ11129)
Sheet 2 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222672 (B)
508 of 1052
 LEGEND
ENGINE CONTROLLER WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX PARTIAL CONNECTOR
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1-3
CONNECTOR J7
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 4-5
PIN FUNCTION
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 6
1 SW POWER BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 7-8
2 GND BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 9-10 CONNECTOR
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 11
3 SW POWER
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 12
4 GND HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB PAGE 13
5 SW POWER CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
CONTROLS PAGE14
6 GND LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 15
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT JOIN ONE WIRE)
9 WATER FUEL SENSOR HVAC PAGE 16
ENGINE 8000 THROUGH 8999 TAN TAN SHEET #
SIGNAL OPTIONS PAGE 17
13 COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
14
15

19 ECU RUN SIGNAL

21

24
25
26
28 MASS AIR FLOW (MAF)
SENSOR FREQUENCY
29
33

34 WATER FUEL SENSOR

GROUND
35 MASS AIR FLOW (MAF)
SENSOR TEMP
45 SW POWER SIGNAL
47 ECU CAN 1 LOW
48 ECU CAN 1 HI
56 PREHEATER SIGNAL Printable Version Click Here

WIRING SCHEMATIC
(SJC MACHINE)
T870 (S/N ASWT11001 - ASWT11577)
(S/N B3BZ11001 - B3BZ11129)
Sheet 3 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222672 (B)
509 of 1052
 UNSWITCHED BATT POWER C408 1240 RED/WHT SHEET 12
(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400 RED/WHT
SHEET 13
1450 RED/WHT 6 1450 RED/WHT C667 DOOR HARNESS
FRC1 FUSE RELAY CENTER 1420 RED/WHT
SP7 SHEET 12
1110 RED/WHT 2 C500 RH KEY SWITCH
FUSE 11 25 A J1B
1070 RED 1120 RED/WHT 1130 RED/WHT 3 GWY CTRLR 1440 RED/WHT
SHEET 12
SP2 C479 LH PANEL (BLACK)
+12V 1025 RED
FUSE 13 25 A
1160 RED/WHT SP36
1150 RED/WHT 3
J2B
BATTERY MEGAFUSE 1180 RED/WHT 2 AUX CTRLR
100.0 Amps
FUSE 15 25A 1080 RED/WHT
1270 RED 1170 RED/WHT SP59 C
J3C
1090 RED/WHT B ACS CTRLR
T4

FUSE 17 25 A
1280 RED 1235 RED/WHT SP58 1260 RED/WHT 48
J5
SHEET 9 1250 RED/WHT 47 DRIVE CTRLR
STARTER
FUSE 4 25 A
1010 RED 1140 RED/WHT
SHEET 16
FRC1 HVAC RELAY
1310 RED

FUSE 1 15 A 1320 RED/WHT

SHEET 15
FRC1 REAR LIGHT RELAY
FUSE 2 20 A 1350 RED/WHT SHEET 15
1340 RED FRC1 FRONT LIGHT RELAY
SP26
1330 RED/WHT
SHEET 15
FRC1 FRONT LIGHT RELAY
FUSE 20 5 A
1335 RED 1345 RED/WHT SHEET 5
FRC1 ENGINE ECU RELAY
FUSE 16 25 A
1325 RED SP1 1300 RED 1035 RED/WHT SHEET 5
FRC 1 ENGINE ECU RELAY
1445 RED/WHT
SHEET 9
FRC1 PRE HEATER RELAY
FUSE 18 25 A
1190 RED 1165 RED/WHT SHEET 7 C426 REMOTE RUN, ACD
1095 RED 1100 RED/WHT SHEET 10
HEATER HOSE RELAY

1220 RED 1230 RED/WHT DCU POWER Printable Version Click Here
SHEET 10

1045 RED 10 1105 RED/WHT 10 SHEET 9

1460 RED/WHT C412 LH HANDLE HORN
SHEET 17
WIRING SCHEMATIC
TAILGATE FANS RELAY PWR C408 CAB-MFR CONN
1040 RED FUSE 22 25 A 1410 RED/WHT
(OPTIONS) (SJC MACHINE)
1490 RED/WHT SHEET 17
1055 RED
SP60
1290 RED
FUSE 24 25 A
1370 RED/WHT
SP24 T870 (S/N ASWT11001 - ASWT11577)
SHEET 13
C408 CAB-MFR CONN
(ACCESSORIES)
(S/N B3BZ11001 - B3BZ11129)
1050 RED
SHEET 5
FRC1 SWITCHED PWR RELAY
Sheet 4 of 18
1030 RED
SHEET 9
FRC1 STARTER RELAY (PRINTED DECEMBER 2016)
Printed In U.S.A. 7222672 (B)
510 of 1052
 FRC1
ENGINE ECU
1525 RNG SHEET 8
SCR INTERCONNECT
SWITCHED POWER J7A ENGINE ECU
+12V RELAY - G
PWR 1506 RNG/WHT 1
SHEET 4 1035 RED/WHT 30 SP73 SP54
87 1540 RNG/WHT 1545 RNG/WHT 1507 RNG/WHT 3

1509 RNG/WHT 1508 RNG/WHT 5

85 86
8005 TAN 45

FRC1 FUSE RELAY CENTER

SHEET 4 1345 RED/WHT
FUSE 21 15 A
1511 RNG/WHT SHEET 9 ENG-CROSSOVER

FUSE 5 25 A C489
1780 RNG/WHT A MFR ACCESSORY

FUSE 6 25 A 1850 RNG/WHT

1760 RNG/WHT SHEET 13 C408 CAB-MFR CONN (FR WIPER)
1700 RNG/WHT SHEET 12 SW12 DPF SWITCH
1705 RNG/WHT SHEET 12 SW12 DPF SWITCH
FUSE 12 15 A
1790 RNG/WHT 1550 RNG/WHT 1620 RNG/WHT
SHEET 17 C408 CAB-MFR CONN (BKT POSITION) SHEET 12 C479 LH PANEL (BLACK)
1940 RNG/WHT
SHEET 12 T13 LH PANEL BUZZER
1930 RNG/WHT
SHEET 12 C499 RH PANEL PTOL
1775 RNG/WHT
SHEET 12 SW1 BRAKE SWITCH
C428 1960 RNG/WHT
FUSE 14 5 A J2B (LT GRAY) SHEET 12 SW9 TRAVEL CONTROL SWITCH
1805 RNG/WHT 1560 RNG/WHT 22 1785 RNG/WHT
AUX CTRLR CAB-MFR HARN CONN 2 SHEET 14 SW4 H/ISO SWITCH
1950 RNG/WHT
SHEET 12 C500 RH PANEL KEY SWITCH
1660 RNG/WHT 2 1660 RNG/WHT 1590 RNG/WHT
SHEET 12 C503 RH DELUXE PANEL
FUSE 7 25 A SP42
1765 RNG/WHT SP25 1795 RNG/WHT 1730 RNG/WHT SP65 1735 RNG/WHT
SHEET 7 C426 REMOTE RUN, ACD
FRC1
1725 RNG/WHT
SWITCHED SHEET 8 C169 ENGINE CAN
POWER RELAY - A FUSE 8 25 A 1580 RNG/WHT
+12V SHEET 13 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
PWR 30
SHEET 4 1050 RED FUSE 23 15 A Printable Version Click Here
87 1815 RNG/WHT 1800 RNG/WHT
SHEET 9 ALT EXCITATION

SHEET 6 2055 BLK GND 85 86 WIRING SCHEMATIC

3450 LBL 21
J1A
GWY CTRLR
C428
(LT GRAY) (SJC MACHINE)
3380 LBL 4 CAB-MFR HARN CONN 2

1920 RNG/WHT 9 1920 RNG/WHT

SP37 1840 RNG/WHT SHEET 7
C449 LH JOYSTICK
T870 (S/N ASWT11001 - ASWT11577)
1830 RNG/WHT
SHEET 7 (S/N B3BZ11001 - B3BZ11129)
C450 RH JOYSTICK
J5
1630 RNG/WHT 50
DRIVE CTRLR Sheet 5 of 18
J3A
1650 RNG/WHT B
1740 RNG/WHT SP52 ACS CTRLR (PRINTED DECEMBER 2016)
1770 RNG/WHT
1710 RNG/WHT
SHEET 14 C537 A22 PUMP HARN (LH SWASH) 7222672 (B)
SHEET 14 C536 A22 PUMP HARN (RH SWASH)

Printed In U.S.A.
511 of 1052
 SHEET 11 2320 BRN

GROUND
C112 HYD OIL FILTER SWITCH
2370 BRN J1B
SHEET 13 GWY CTRLR
C408 CAB-MFR CONN (SEATBAR SENSOR)
2220 BRN SP12 2230 BRN 17
SHEET 11
C108 HYD TEMP SENDER
2190 BRN
2 SHEET 11
2001 BLK C105 HYD CHG PRESSURE SENDER
4 2002 BLK SP53 2820 BLK SP75 2805 BLK 2180 BRN
J7A SHEET 9
ENG ECU CTRLR 6 2003 BLK C355 FUEL HARN (FUEL SENDER)
2150 BRN
SP50 2235 BLK SHEET 9
27 2040 BLK C405 AIR FILTER SWITCH
T32 2004 BLK J5
ECU CASE GND DRIVE CTRLR 28 2490 BLK 2690 BRN
SHEET 9
2880 BLK C408 CAB-MFR CONN (HAND THRTL)
SHEET 10 2695 BRN
SHEET 9
C120 SCR-MFR CONN J3A H 2020 BLK C115 FOOT THROTTLE
ACS CTRLR
2430 BRN 18
2080 BLK SHEET 9
SHEET 7 SP57 ENGINE TEMP GND
C449 LH JOYSTICK H 2270 BLK 2240 BLK T6
2070 BLK J3C BATT GND
SHEET 7 C408 ACS CTRLR J 2260 BLK
C450 RH JOYSTICK (BLACK)
2920 BLK CAB-MFR HARN CONN 1
SHEET 12 2765 BLK
C479 LH PANEL (BLACK) SHEET 15
2940 BLK 2950 BLK 10 2950 BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 12
C499 PTOL 2745 BLK
SP3 SHEET 16
2960 BLK 16 C408 CAB-MFR CONN (HVAC)
SHEET 12 2510 BLK 2110 BLK
C500 RH PANEL KEY SWITCH J1B 2790 BLK T8
GWY CTRLR 15 2500 BLK SHEET 13 BATT GND
2250 BLK C408 CAB-MFR CONN (ACCESSORIES)
SHEET 12
C503 RH DELUXE PANEL 2780 BLK
2065 BLK C428 SHEET 17
SHEET 12 16 C408 CAB-MFR CONN (OPTIONS)
(LT GRAY) 2540 BLK
SW12 DPF SWITCH SP28 2730 BLK
2930 BLK CAB-MFR HARN CONN 2 J2B 15 SHEET 13
SHEET 12 AUX CTRLR 2550 BLK 2090 BLK
SW1 BRAKE SWITCH C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
2830 BLK 2900 BLK 1 2900 BLK
SHEET 17
SW6 BKT POSITION SWITCH
2700 BLK 2770 BLK
SHEET 12 SHEET 17
SW9 TRAVEL CONTROL SWITCH C355 FUEL HARN (PWR BOB/AC)
2785 BLK 2200 BLK
SHEET 17 SHEET 11
C126 HORN C425 BRAKE
2620 BLK
SHEET 15 C103 C489
T16 RH REAR LIGHT B 2720 BLK
TAILGATE HARN MFR ACCESSORY
2650 BLK SP6
SHEET 14
T20 BU ALARM 2600 BLK B 2600 BLK 2390 BLK 10 T1 2015 BLK T10
2640 BLK BATT GND SHEET 9 ENGINE
SHEET 15 2400 BLK 14 ALTERNATOR GROUND GROUND
C602 LH REAR LIGHT SHEET 9
LEFT TAILGATE FANS GND
2610 BLK 2405 BLK 14
SHEET 15 SHEET 9
C603 RH REAR LIGHT RIGHT TAILGATE FANS GND
2630 BLK 2455 BLK
SHEET 15 SHEET 17
T18 LH REAR LIGHT C423 BKT POSITION SOLENOID SP27
2710 BLK 2300 BLK
SHEET 7
C426 REMOTE RUN, ACD Printable Version Click Here
SHEET 8 2715 BLK
C169 ENGINE CAN
2290 BLK
WIRING SCHEMATIC
SHEET 15 2045 BLK SHEET 16
FRC1 REAR LIGHT RELAY D4 COMPRESSOR DIODE
2295 BLK 18
(SJC MACHINE)
SHEET 9
SHEET 15
FRC1 FRONT LIGHT RELAY
2115 BLK SP55 TAILGATE FANS RELAY GND 2105 BLK 18 T870 (S/N ASWT11001 - ASWT11577)
SHEET 5
2055 BLK
FRC1 SWITCHED POWER RELAY
(S/N B3BZ11001 - B3BZ11129)
2030 BLK
SHEET 16
FRC1 HVAC RELAY Sheet 6 of 18
SHEET 9 2005 BLK
FRC1 STARTER RELAY (PRINTED DECEMBER 2016)
2120 BLK
SHEET 15
FRC1 FRONT LIGHT RELAY
7222672 (B)
Printed In U.S.A.
512 of 1052
 CAN BUS
C408
J1B (BLACK)
GWY CTRLR CAB-MFR HARN CONN 1

8 9260 PUR 9230 PUR SP31 9250 PUR SP79 9270 PUR SP19 9220 PUR 4 9220 PUR SP18 9410 PUR SP39 9430 PUR SP35 9450 PUR 9460 PUR 4
CAN LO C479
9 9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
SP30 SP80 SP20 SP17 SP38 SP34 RE019
RE016
120 OHM 120 OHM
0.5 W 0.5 W
RESISTOR RESISTOR
J5 9440 PUR 4
DRIVE CTRLR C503
9340 PUR/WHT 2 RIGHT DELUXE PANEL
9290 PUR 22
9190 PUR/WHT 12
1830 RNG/WHT 1
SHEET 5 C450
2070 BLK 2
J3A SHEET 6 RIGHT JOYSTICK
ACS CTRLR 9320 PUR/WHT 3 SHEET 14
9420 PUR 4
9240 PUR E
9140 PUR/WHT D
1840 RNG/WHT 1
SHEET 5 C449
2080 BLK 2
SHEET 6 LEFT JOYSTICK
J2B 9300 PUR/WHT 3
AUX CTRLR SHEET 14
9400 PUR 4
9280 PUR 8
J2B C426 9180 PUR/WHT 9
AUX CTRLR Remote Run Tool, ACD
Printable Version Click Here
14 9500 PUR/WHT A
CAN HI
CAN LO
20 9600 PUR B WIRING SCHEMATIC
(SJC MACHINE)
J1B
GWY CTRLR T870 (S/N ASWT11001 - ASWT11577)
21 3090 LBL D
REMOTE RUN KEY
(S/N B3BZ11001 - B3BZ11129)
C
SHEET 5
1735 RNG/WHT
1165 RED/WHT
E
F
SWITCHED POWER Sheet 7 of 18
SHEET 4 UNSWITCHED POWER
2710 BLK G
SHEET 6 GROUND (PRINTED DECEMBER 2016)
Printed In U.S.A. 7222672 (B)

513 of 1052
 J7A
ECU CNTRLR
ENGINE CAN BUS C121
DOSING CONTROL UNIT
SP81 SP90
47 9200 PUR 9215 PUR 9415 PUR 9210 PUR SP67 9265 PUR SP71 9275 PUR SP70 9245 PUR 65
CAN LO 120 Ohm Terminator
48 9100 PUR/WHT 9115 PUR/WHT 9315 PUR/WHT 9110 PUR/WHT SP68 9165 PUR/WHT SP72 9175 PUR/WHT SP69 9145 PUR/WHT 66 Resistor internal to Controller
CAN HI
RE014 SP82 SP91
120 OHM
0.5 W
RESISTOR
J1B
GWY CTRLR C163
NOx PRETREATMENT
9205 PUR 20
9105 PUR/WHT 14 9295 PUR 3
9195 PUR/WHT 4
2835 BLK 2
2875 BLK 5
1

SHEET 10 2870 BLK

NOx GROUND SP78 C164
NOx POST TREATMENT

2815 BLK 2
9285 PUR 3
9185 PUR/WHT 4
5
1635 RNG/WHT 1

1525 RNG 1645 RNG/WHT

SHEET 5
SP76
SCR INTERCONNECT
C161
DEF TANK
1640 RNG/WHT 4
C169
9225 PUR 1
ENGINE CAN
9125 PUR/WHT 2
1 1725 RNG/WHT 3
SHEET 5 SHEET 10 2825 BLK
2 2715 BLK SHEET 6
3 9155 PUR/WHT C121
4 9255 PUR
DOSING CONTROL UNIT
WIRING SCHEMATIC
5 9720 PUR/WHT 82
6 9820 PUR 60 (SJC MACHINE) Printable Version Click Here
T870 (S/N ASWT11001 - ASWT11577)
(S/N B3BZ11001 - B3BZ11129)
Sheet 8 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222672 (B)

514 of 1052
 1030 RED
FRC1
STARTER
+12V RELAY - M
PWR 30
C111
MFR-BCT HARN CONN
STARTER
ENGINE
SHEET 4 87 8200 TAN A 8220 TAN S M
B SHEET 4
3560 LBL B 3560 LBL R
GND 85 86 8210 TAN C 1015 RED
SHEET 6 2005 BLK 1800 RNG/WHT
FUSE 12
SHEET 5
C115
7 8210 TAN FOOT THROTTLE B
22 D ALTERNATOR G
3560 LBL C405 1800 RNG/WHT
2150 BRN B AIR E
GND EXCITATION
SHEET 6 FILTER
16 3150 LBL A SIG SWITCH F 2015 BLK
SHEET 6
5695 YEL (NC) C +5V PWR
SHEET 13 ENGINE GROUND TERMINAL
J1A 33 3695 LBL A
SIG
GWY CTRLR 2695 BRN B GND FRC1
SHEET 6 TAILGATE FANS FUSE 15 A
25 3105 LBL 18 RELAY - C
12 3100 LBL 18 C119
C104 LEFT TAILGATE
87 A B C171
TAILGATE FANS CONN FAN CONN
TAILGATE FANS RELAY PWR 1105 RED/WHT 10 87A 8110 TAN 14 1 8110 TAN 14 8125 TAN 14 A
LEFT
SHEET 4 30 2 B
TAILGATE 2400 BLK 14 2400 BLK 14
2295 BLK 18 85 86 FANS GND SHEET 6 8105 TAN 14 3 8105 TAN 14
TAILGATE FANS RELAY GND
9 SHEET 6 2405 BLK 14 4 2405 BLK 14
8100 TAN 18 RIGHT FUSE 15 A
TAILGATE SHEET 6 C113
J1B
C355 FANS GND RIGHT TAILGATE
GWY CTRLR FUEL HARN A B C172
C406 FAN CONN
12 3180 LBL C A 8135 TAN 14 A
3180 LBL SIG
FUEL SENDER B
2180 BRN D 2180 BRN B GND (30 - 270 OHM)
10 SHEET 6
3690 LBL
C428
C120 (LT GRAY)
SHEET 6 ENGINE C114 INTAKE HEATER
2430 BRN 18 2 CAB-MFR HARN CONN 2 +12V CONTACTOR
TEMP HAND THROTTLE
18 T29 PWR FUSE 150 A
3110 LBL 18 1 SENSOR SHEET 13 5690 YEL 7 5690 YEL C +5V PWR 30
(950-4400 OHM) 1060 RED 1 2 1065 RED/WHT 87 8515 TAN SP77 8500 TAN
3690 LBL 6 A T14
3690 LBL SIG T26 T27
8510 TAN 85 86 1445 RED/WHT
2690 BRN 8 2690 BRN B GND
4 8007 TAN SHEET 4
SHEET 6 D 8505 TAN
E T31

J7A F
ENG ECU CTRLR
8020 TAN SP74
SHEET 10
19 8008 TAN
C100
9 1 Printable Version Click Here
3865 LBL SIG WATER IN FUEL SENSOR
34 2865 BRN 2 (FUEL FILTER)

56
GND
WIRING SCHEMATIC
C118 (SJC MACHINE)
28 8013 TAN ENG-CROSSOVER
35 8014 TAN ENG-CROSSOVER SHEET 5 1511 RNG/WHT 1 TO C154 - Pin 1
See Sheet 18 of 18
T870 (S/N ASWT11001 - ASWT11577)
8013 TAN 2 FREQ TO MAF - Pin 1

8014 TAN 3 TEMP

See Sheet 18 of 18
TO MAF - Pin 4
See Sheet 18 of 18
(S/N B3BZ11001 - B3BZ11129)
3420 LBL 4
T42 TO GLOW PLUG - ECU Pin 179
See Sheet 18 of 18
Sheet 9 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222672 (B)
515 of 1052
 DOSING CONTROL UNIT HOSE HEATER MAIN
1100 RED/WHT 30
87 8090 TAN
SHEET 4 T33
2975 BLK 85 86
DCU CASE GND

2915 BLK
C121
DOSING CONTROL UNIT

1230 RED/WHT SP62 1245 RED/WHT 5 93 8310 TAN

SHEET 4 1265 RED/WHT 6
C123
1255 RED/WHT 73 67 HOSE 1 HEATER

2310 BRN
1275 RED/WHT 51 68 7998 WHT SP87 8120 TAN 1

89 8320 TAN 2
2880 BLK SP63 2925 BLK 1 90
SHEET 6 7999 WHT
C120 SCR-MFR CONN SHEET 8 2825 BLK 2935 BLK 2 HOSE 1 HEATER
2945 BLK 7 72 8340 TAN SP88 8330 TAN 30

8140 TAN
87 2955 BLK SP86
Nox Ground 2870 BLK 2855 BLK 29
SHEET 8 C124
2145 BRN 85 86 HOSE 2 HEATER
8020 TAN 22
94 8550 TAN 1
SHEET 9
8240 TAN 2
53 2135 BRN SP85
C155
1 2170 BRN 75 HOSE 2 HEATER
TANK HEATING VALVE

8150 TAN
4 8540 TAN 92 49 8260 TAN SP89 8250 TAN 30
87 2965 BLK
C156 C125

2985 BLK
2140 BRN 85 86 HOSE 3 HEATER
REDUCTION AGENT 1 8850 WHT 80
50 8560 TAN 1
METERING VALVE 2 8950 BLK 58
2165 BLK 2
59 8350 TAN
C157
1 8900 TAN 83 HOSE 3 HEATER
CATALYST TEMPERATURE
2 2025 BRN 61 27 8370 TAN SP61
SCR INLET 8360 TAN 30
87
C158
1 8520 TAN 62 85 86
2125 BRN
CATALYST TEMPERATURE
SCR OUTLET 2 2160 BRN 84 28 8600 TAN
C159
1 8800 TAN 31 C122
ENVIRONMENTAL TEMPERATURE SUPPLY MODULE
2 2050 BRN 9
4 1690 RNG/WHT 11
HEATER BATT+ Printable Version Click Here
C160 3 8650 TAN 12
HEATER SIGNAL
CATALYST TEMPERATURE
1 8530 TAN 18 TXL 34
55 1695 RNG/WHT 3
PUMP MOTOR BATT +
WIRING SCHEMATIC
DOC INLET 2 2075 BRN 18 TXL 12
2
76 8700 TAN
4
PUMP MOTOR CONTROL SIGNAL (SJC MACHINE)
54 2095 BRN PUMP MOTOR GND
77 1680 RNG/WHT 5
PURGING PUMP BATT +
T870 (S/N ASWT11001 - ASWT11577)
6
78 8750 TAN
10
PURGING PUMP SIGNAL (S/N B3BZ11001 - B3BZ11129)
17 1685 RNG/WHT PRESSURE SENSOR BATT+
39 3000 LBL 9
PRESSURE SENSOR SIGNAL
Sheet 10 of 18
40 2085 BRN 8
PRESSURE SENSOR GND
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222672 (B)

516 of 1052
 HYDRAULICS
C425

B C308
BRAKE
4200 LGN A 4200 LGN A SOLENOID TRACK 2 SPEED
2200 BLK C 2200 BLK B 9.8 OHM ADAPTER (SEE
SHEET 6 ADDITIONAL
12 V
WHEEL 2 SPD ADP HARNESS 7159366 OPTIONS DWG)
TRACK 2 SPD HARNESS 7214627
TRACK SINGLE SPD BRAKE ADP HARNESS 7234968

C108
2220 BRN B HYDRAULIC
GND
SHEET 6 TEMPERATURE
32 3220 LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320 LBL A SIG HYDRAULIC OIL
GWY CTRLR 2320 BRN B GND FILTER SWITCH (NC)
SHEET 6

C446
18 2910 BRN 2 GND HYDRAULIC
4010 LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410 BRN B GND HYDRAULIC LOCK
4410 LGN A SIG SOLENOID
9.8 OHM 12 V
C105
2190 BRN B GND HYDRAULIC
SHEET 6
3190 LBL C SIG CHARGE
5190 YEL A +8V PWR PRESSURE
0.5-7.5V
4200 LGN

19 13 1 23 6
J1B +8V
GWY CTRLR Printable Version Click Here

C418
WIRING SCHEMATIC
J2A
AUX CTRLR
18 2330 BRN
4330 LGN
2
1
GND
SIG
FRONT ROD
SOLENOID (MALE) (SJC MACHINE)
3.3 OHM PWM
C419 T870 (S/N ASWT11001 - ASWT11577)
1 2340 BRN 2 GND FRONT BASE
4340 LGN 1 SIG SOLENOID (FEMALE)
3.3 OHM PWM
(S/N B3BZ11001 - B3BZ11129)
Sheet 11 of 18
19 13
(PRINTED DECEMBER 2016)
J2B
Printed In U.S.A. AUX CTRLR 7222672 (B)

517 of 1052
SHEET 5
1940 RNG/WHT

7040 WHT
T13
BUZZER (+)

LEFT PANEL
BUZZER
CAB DISPLAY C499
Press To Operate Loader
(PTOL)
C479
T2
LEFT PANEL (BLACK) 1930 RNG/WHT 1
BUZZER (-) SHEET 5 SWITCHED POWER
10 C408 2940 BLK 3
7040 WHT BUZZER SHEET 6 GROUND
(BLACK)
2920 BLK 2 CAB-MFR HARN CONN 1
SHEET 6 GROUND
1960 RNG/WHT 1440 RED/WHT 1
SHEET 5 SHEET 4 UNSWITCHED POWER 20 3030 LBL 1 3030 LBL 2
PTOL OUTPUT
SW9 1620 RNG/WHT 5 SWITCHED POWER
SHEET 5 19 2380 BRN 12 2380 BRN 4
TRAVEL CONTROL PTOL LED
SWITCH (OPTIONAL) 3400 LBL 11 LEFT BLINKER INPUT J1A
SHEET 17
GWY CTRLR
5 6 SHEET 17
3500 LBL 8 C500
RIGHT BLINKER INPUT RIGHT PANEL - KEY SWITCH
4
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 2 8130 TAN 2
SHEET 6 TRAVEL CONTROL INPUT START
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610 LBL 4 5
SHEET 5 1775 RNG/WHT 6
2930 BLK C480 J1B 22 3040 LBL 14 4
SHEET 6 LEFT PANEL (GRAY) 3040 LBL RUN/ENTER SWITCH
GWY CTRLR
3620 LBL 12
SHEET 13 DOOR SIGNAL
11 1950 RNG/WHT 5
SHEET 5 SWITCHED POWER
10 1420 RED/WHT 1
SHEET 4 UNSWITCHED POWER
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
8
SW12
DESOX INHIBIT SWITCH 7 C503
(OPT KIT) 6 RIGHT PANEL DELUXE DISPLAY
1700 RNG/WHT 7 9 8050 TAN 4 1590 RNG/WHT 5
SHEET 5 SHEET 5 SWITCHED POWER
1705 RNG/WHT 10 8 8055 TAN 5
SHEET 5 DESOX INHIBIT LAMP 1240 RED/WHT 1
9 SHEET 4 UNSWITCHED POWER
2065 BLK 2 4 8070 TAN
SHEET 6 DESOX INHIBIT 2250 BLK 3
1 SHEET 6 GROUND
8060 TAN 1 6
3

WIRING SCHEMATIC
Printable Version Click Here
(SJC MACHINE)
T870 (S/N ASWT11001 - ASWT11577)
(S/N B3BZ11001 - B3BZ11129)
Sheet 12 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222672 (B)

518 of 1052
 *
CAB
DLX CAB HARN 7253375 ONLY
C438
(DK GRAY) (NOT IN STD CAB HARN)
CAB-MFR HARN CONN 3

1850 RNG/WHT 2 1850 RNG/WHT

* C212
POWER
SHEET 5 SOCKET
2795 BLK 1 GND
1375 RED/WHT 2 +12V PWR
C408
(BLACK)
CAB-MFR HARN CONN 1

1370 RED/WHT 7 1370 RED/WHT SP45

*
1390 RED/WHT
T37
DOME LIGHT (+)
SHEET 4
DOME
C129 2010 BLK LIGHT
SP41
CAB ACCESSORY

1580 RNG/WHT 1580 RNG/WHT SP8

1210 RED/WHT A +12V BATT PWR * T38
DOME LIGHT (-)
5 1865 RNG/WHT B +12V SW PWR
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 17
1885 RNG/WHT SHEET 17
SP44 2210 BLK SHEET 17
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 17
2060 BLK SHEET 14
C428
(LT GRAY) * C667
DOOR HARNESS
CAB-MFR HARN CONN 2 (SEE ADDITIONAL
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
WIPER SWITCH, MOTOR SWITCHED POWER
3620 LBL 4
SHEET 12 DOOR SIGNAL
1400 RED/WHT 5
SHEET 4 DOOR UNSW PWR
6
C482 SEATBAR 2840 BLK 2
WIPER MOTOR GROUND
J1B
GWY CTRLR SHEET 6
2370 BRN 4 2370 BRN A GND SENSOR 7310 WHT 3
WASHER SIGNAL

11 3370 LBL 5 3370 LBL B SIG

24 5100 YEL SP13 5370 YEL 3 5370 YEL C

+5V
+5V PWR

HARNESS WASHER PUMP

SHEET 9 5690 YEL Printable Version Click Here
7253378
SHEET 9 5695 YEL
WIRING SCHEMATIC
* C252
A
C253
1
PWR (SJC MACHINE)
7310 WHT WASHER

2845 BLK B 2845 BLK 2 GND

MOTOR
T870 (S/N ASWT11001 - ASWT11577)
(S/N B3BZ11001 - B3BZ11129)
Sheet 13 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222672 (B)
519 of 1052
 CONTROLS
SW4 J5
HAND/FOOT DRIVE CTRLR
(ACS)
H/ISO 33
(SJC, AWS) 34
SWITCH
SHEET 5
1785 RNG/WHT 2 1
3 40 SP11
+5V 5890 YEL
2060 BLK 5 6
SHEET 13
4
C438 23
J5 (DK GRAY) 24
DRIVE CTRLR CAB-MFR HARN CONN 3

6 4235 LGN 7 4235 LGN C536

5810 YEL 2 C543 A22 PUMP HARNESS
16 4275 LGN 8 4275 LGN
29 SP56 2810 BRN 4 2810 BRN 1
4 9 4550 LGN 2890 BRN GND
RIGHT
4550 LGN 8 3 3810 LBL 3
3810 LBL SIG SWASHPLATE
1710 RNG/WHT 1 1710 RNG/WHT 2 +12V PWR
SHEET 5
C103 C537
TAILGATE HARN 5860 YEL 2 C542
T19 TERMINAL (+)
36 7100 WHT C 7100 WHT 2860 BRN 4 2860 BRN 1 GND LEFT
BACK UP 7 3860 LBL 3 3860 LBL 3 SIG SWASHPLATE
2650 BLK ALARM
SHEET 5 1770 RNG/WHT 1 1770 RNG/WHT 2 +12V PWR
SHEET 6
T20 TERMINAL (-) C501 C546
43 4260 LGN 1 4260 LGN 1
RIGHT FORWARD DRIVE
42 2660 BRN 2 2660 BRN 2
C460
1 1830 RNG/WHT 1 +12V PWR
C547
C450 2 2070 BLK 2 GND 44 3 4250 LGN 1
RIGHT JOYSTICK
RIGHT 4250 LGN
RIGHT REVERSE DRIVE
3 9560 PUR/WHT 3 CAN HI HANDLE 45 2650 BRN 4 2650 BRN 2
4 9660 PUR 4 CAN LO
C545
31 4280 LGN 5 4280 LGN 1
C459 41 2680 BRN 6 2680 BRN 2 LEFT REVERSE DRIVE
1 1840 RNG/WHT 1 +12V PWR

C449 2 2080 BLK 2 GND C544

LEFT JOYSTICK 3 9540 PUR/WHT 3 CAN HI
LEFT 21 4270 LGN 7 4270 LGN 1
11 8 2670 BRN 2 LEFT FORWARD DRIVE
HANDLE 2670 BRN
4 9640 PUR 4 CAN LO

SUSP SEAT JOYSTICK HARNESS 7163706 C474

C429 26 4210 LGN A BRAKE CONN
LIFT ACTUATOR USED WITH ROADLIGHT KIT
4600 LGN 5
6
4610 LGN 8
7
G 2970 BRN SP5 2980 BRN 1 GND
J3A
ACS CTRLR 4
A 5970 YEL SP29 5980 YEL 3 Printable Version Click Here
+5V PWR
+5V
J3B
ACS CTRLR
3980 LBL 2 SIG WIRING SCHEMATIC
J3C
H
E 3990 LBL
C427
2 SIG
TILT ACTUATOR (SJC MACHINE)
ACS CTRLR
5990 YEL
4
3 +5V PWR
T870 (S/N ASWT11001 - ASWT11577)
F
6
D 2990 BRN 1 GND (S/N B3BZ11001 - B3BZ11129)
A 4640 LGN 5

K
7
8
Sheet 14 of 18
4650 LGN

(PRINTED DECEMBER 2016)

Printed In U.S.A. 7222672 (B)
520 of 1052
 C434-1
2735 BLK B GND LEFT FRONT

LIGHTS
C408
6100 PNK A SIG WORK LIGHT
(BLACK)
CAB-MFR HARN CONN 1 37.00 Watts
C434-2
2765 BLK 9 2765 BLK SP14 2750 BLK B GND
SHEET 6 LEFT FRONT
6110 PNK A SIG WORK LIGHT
50.00 Watts

C435-1
FRC1 6000 PNK 8 6000 PNK SP15 6120 PNK A RIGHT FRONT
SIG
FRONT WORK WORK LIGHT
2760 BLK B GND
LIGHTS 37.00 Watts
RELAY- J
C438 C435-2
(DK GRAY) 6130 PNK A SIG
SHEET 4 1350 RED/WHT 30 CAB-MFR HARN CONN 3 RIGHT FRONT
87 6610 PNK 2705 BLK B GND WORK LIGHT
50.00 Watts
13 6610 PNK SP64
SHEET 6 2120 BLK 85 86

FRC1
FRONT WORK

6630 PNK
LIGHTS
RELAY - K C103
+12V TAILGATE HARN C603
PWR 2610 BLK 2 GND
1330 RED/WHT 30 SP10 SHEET 6 RIGHT REAR
SHEET 4 87 6340 PNK 6310 PNK A 6310 PNK 6320 PNK 1 SIG
TAIL LIGHT
GND 85
SP49
2115 BLK 86 C602
SHEET 6
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
Printable Version Click Here

SHEET 6
2620 BLK
T16 TERMINAL (-)
GND RIGHT REAR
WIRING SCHEMATIC
6210 PNK SIG WORK LIGHT
FRC1
REAR LIGHT T15 TERMINAL (+)
(SJC MACHINE)
+12V RELAY - E
1320 RED/WHT PWR 30 T17 TERMINAL (+) T870 (S/N ASWT11001 - ASWT11577)
SHEET 4 87 6200 PNK H 6200 PNK SP96 6220 PNK SIG LEFT REAR

2045 BLK
GND 85 86 SHEET 6 2630 BLK GND WORK LIGHT (S/N B3BZ11001 - B3BZ11129)
SHEET 6 T18 TERMINAL (-)
Sheet 15 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A.
7222672 (B)

521 of 1052
 * C610

HVAC
2440 BLK 2 GND HVAC DUCT
7440 WHT 1 SIG FAN

2560 BLK * C483

C BLK
7420 WHT A DBL POTENTIOMETER

* DLX CAB HARN 7253375 ONLY 7425 WHT B WHT

(TEMP CONTROL
SWITCH)

(NOT IN STD CAB HARN) * C635

D SIG
2130 BLK C GND HEATER
7430 WHT A +12V PWR VALVE
SP48 B
E
F

FRC1
HVAC
C438
(DK GRAY)
*BLOWER
SW10

+12V RELAY - B CAB-MFR HARN CONN 3 SWITCH

PWR 30 OFF
1140 RED/WHT
SHEET 4 87 1500 RNG/WHT 10 1500 RNG/WHT 5 2
1
GND 85 86 4
2030 BLK
SHEET 6 7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
3 7520 WHT 2 7.50 Amps Med BLOWER
7050 WHT MOTOR
SW11 7510 WHT 3 5.00 Amps Low
J1A
30 3050 LBL
SHEET 6
2745 BLK 11 2745 BLK *
AC SWITCH 2580 BLK 4
GWY CTRLR SP16
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT SP40 7020 WHT 12
C630
* 3
THERMOSTAT

AC EVAPORATOR C350 2570 BLK 2 Printable Version Click Here

SWITCH B 7023 WHT 7020 WHT 1
A 7024 WHT WIRING SCHEMATIC
C486
7025 WHT 1 SIG
MAGNET CLUTCH
(SJC MACHINE)
2 GND

SHEET 6
2290 BLK 2280 BLK
(COMPRESSOR)
T870 (S/N ASWT11001 - ASWT11577)
D4
(S/N B3BZ11001 - B3BZ11129)
Sheet 16 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222672 (B)

522 of 1052
 C355
FUEL HARN
C428
(LT GRAY)
CAB-MFR HARN CONN 2
OPTIONS
SIG
# C607
1 4470 LGN E 4470 LGN 11 4470 LGN
#
DLX FUEL HARN 7266824 ONLY
POWER BOB
CLOSE GND 2 2470 BLK 2770 BLK B 2770 BLK
SHEET 6 4480 LGN (NOT IN STD FUEL HARN 7149219)
SW5
*POWER 2 1
#
GND
C606
2 2480 BLK
BOBTACH
SWITCH 5
3
4
6
* DLX CAB HARN 7253375 ONLY
POWER BOB
OPEN
SIG 1 4480 LGN F 4480 LGN 10
(NOT IN STD CAB HARN)
6010 PNK 13 6010 PNK

1380 RED/WHT
1550 RNG/WHT 12 1550 RNG/WHT
SHEET 5

C438
(DK GRAY)
CAB-MFR HARN CONN 3 1200 RED/WHT
SP43
C411
B
SHEET 4
1410 RED/WHT 1 1410 RED/WHT 1430 RED/WHT X
L
* T3
FLASHER
LEFT HANDLE CONN
C SHEET 12 3500 LBL
(FLASHER) 5 WAY SP21 D1
A 6515 PNK 6500 PNK 6 6500 PNK 6530 PNK
*BEACON
SW2

6570 PNK
(SEE ADDITIONAL E
OPTIONS DWG) D 6415 PNK SP22 6400 PNK 3 6400 PNK
D2 6430 PNK SWITCH
3400 LBL 2725 BLK 6
C103 SHEET 12 *HAZARD
SW3
2
1
6700 PNK
4
1
5
2
TAILGATE HARN 3
SWITCH 4 3
5
EURO TAIL LIGHTS E 6410 PNK (PINS 3 & 6 2850 BLK SP46
INTERNALLY 6
D
(SEE ADDITIONAL
OPTIONS DWG)
6510 PNK
INSULATED) * C670
E
2780 BLK 4 2780 BLK 2780 BLK D
SHEET 6 2420 BLK BEACON/FLASHER
C423
3 6440 PNK F EXTERIOR HARNESS
BUCKET SIG A 4450 LGN D3 4455 LGN 5 4455 LGN 1
4
2 * SW6
BUCKET 6540 PNK B (SEE ADDITIONAL
OPTIONS DWG)
POSITION 2830 BLK 5 POSITION C
SOLENOID GND B 2450 BLK 2455 BLK SHEET 6 SWITCH A
SHEET 6 6
9.8 OHM
C408
(BLACK) * C676

LEFT HANDLE C412

CAB-MFR HARN CONN 1 SHEET 6
2785 BLK
C126
B GND LEFT
*+
C279
1 7820 WHT
RADIO CONN
3
C277
(HORN) 2 WAY
(SEE ADDITIONAL
B
A 1460 RED/WHT
7210 WHT 13 7210 WHT A SIG HORN SPEAKER
-
2 7830 WHT 4
* 1
OPTIONS DWG) SHEET 4 2
C497
SJC RIGHT
*-
C278
2 7810 WHT 6 3
AIR RIDE
SEAT
5 7200 WHT C SPEAKER 1 7800 WHT 5 1510 RNG/WHT 4 PWR
HORN/BLINKER SHEET 13
4 6420 PNK A + 1 2210 BLK 5 GND
(SEE ADDITIONAL 1885 RNG/WHT SHEET 13
3 6520 PNK B SHEET 13 6
J2A OPTIONS DWG) 2885 BLK 2
SHEET 13
AUX CTRLR
C415
26 2460 BRN B GND HIGH FLOW
4460 LGN A SIG
SOLENOID
7.5 OHM 12 V WIRING SCHEMATIC
J2B
26 Printable Version Click Here
AUX CTRLR (SJC MACHINE)
J1A 26 2350 BRN
C441
2 GND TWO SPEED TRACK 2 SPEED
T870 (S/N ASWT11001 - ASWT11577)
ADAPTER
GWY CTRLR 4350 LGN 1 SIG SOLENOID
5.1 OHM 12 V (SEE ADDITIONAL
OPTIONS DWG)
(S/N B3BZ11001 - B3BZ11129)
J1B 26
GWY CTRLR Sheet 17 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222672 (B)
523 of 1052
 SUPPLIED
TO C118 - Pin 4
See Sheet 9 of 18 PRE HEATER 179 J7B
ENG ECU CTRLR
(DOOSAN HARNESS)

C131
106 TEMP SENSOR 2 EXHAUST GAS

ENGINE
123 TEMP SENSOR
SENSOR RETURN 2
BEFORE TURBO

C151
1 EGR VREF3 164

HARNESS
C133
5 POSITION SIGNAL 116 194 TEMP SENSOR 4
EGR VALVE INTAKE
DC MOTOR 3 POSITION RETURN 172 169 SENSOR RETURN 4 MANIFOLD TEMP
6 H BRIDGE POS 192
2 H BRIDGE NEG 193

C149 TO C118 - Pin 33

1 COOLANT TEMP SENSOR 109 See Sheet 9 of 18
COOLANT TEMP 4 INTAKE
SENSOR 2 COOLANT RETURN 145 THROTTLE
120 VREF 3 THROTTLE POSITION 1
C148 137 POSITION SENSOR GRD 3
1 FUEL TEMP SENSOR 110 TO C118 - Pin 2 2
FUEL TEMP
SENSOR 2 FUEL RETURN 146 See Sheet 9 of 18
C136
C147 165 VREF3 OIL PRESSURE
1 131 OIL PRESSURE &
ENGINE BLOCK SENSOR SIGNAL 111 OIL PRESSURE SENSOR TEMPERATURE
ACCELEROMETER 1 2 SENSOR RETURN 130 148 SENSOR
RETURN GRD
SHIELD 128
104 OIL TEMPERATUR SENSOR
C146
1 SENSOR SIGNAL 132
ENGINE BLOCK
ACCELEROMETER 2 2 SENSOR RETURN 133
SHIELD 129

C145
CRANKSHAFT CRANK SENSOR POS 160
POSITION 136
CRANK SENSOR NEG
SENSOR
C144
C138
1 SENSOR RETURN 147
141 VREF2 INTAKE PRESS B
CAM SHAFT 2 159 Printable Version Click Here
POS SENSOR
SENSOR 112 INTAKE PRESSURE SENSOR A
TO C118 - Pin 1 INLET TEMP
3 VREF1 CAM
See Sheet 9 of 18
167 INTAKE PRESSURE RETURN D PRESSURE
SENSOR
WIRING SCHEMATIC
C143

RAIL PRESSURE
1 RAIL PRESS URE SENSOR 135
(SJC MACHINE)
2 SENSOR RETURN 119
SENSOR
3 VREF 1 SENSOR 138
127 FUEL INJECTOR HSDA
C139
T870 (S/N ASWT11001 - ASWT11577)
CYL 1
C141
FUEL INJECTOR HSDB 151
126 FUEL INJECTOR LSD1A
(S/N B3BZ11001 - B3BZ11129)
CYL 3 175 C140
FUEL INJECTOR LSD1B

C142
150
174
FUEL INJECTOR HSDB
CYL 2
Sheet 18 of 18
FUEL INJECTOR LSD2B
FUEL INJECTOR HSDA 103
CYL 4
FUEL INJECTOR LSD2A 125 C154 (PRINTED DECEMBER 2016)
Printed In U.S.A. 177 PWM 2
INLET METERING 7222672 (B)
TO C118 - Pin 1 1 VALVE
See Sheet 9 of 18
524 of 1052
 CONNECTOR ASSIGNMENTS
NUM NUM NUM NUM
CONN DESCRIPTION OF SHEET CONN DESCRIPTION OF SHEET CONN DESCRIPTION OF SHEET CONN DESCRIPTION OF SHEET
PINS PINS PINS PINS
C100 WATER IN FUEL SENDER 2 9 C278 RIGHT SPEAKER 2 17 C483 TEMP CONTROL SWITCH 3 16 RC1 FRONT WORK-LIGHTS RELAY 4 15
C103 TAILGATE HARNESS 8 6,14,15,17 C279 LEFT SPEAKER 2 17 C486 AC COMPRESSOR 2 16 RC2 FRONT WORK-LIGHTS RELAY 4 15
C104 TAILGATE FANS 4 9 C308 BRAKE SOLENOID 2 11 C489 MFR ACCESSORY 2 5,6 SW1 BRAKE SWITCH 6 12
C105 HYD CHARGE PRESSURE 3 11 C350 AC EVAPORATOR SWITCH 2 16 C497 SJC HORN/BLINKER 3 17 SW2 BEACON SWITCH 6 17
SENSOR
C108 HYD TEMPERATURE SENDER 2 11 C355 FUEL HARNESS 6 9,17 C499 PTOL 4 12 SW3 HAZARD SWITCH 6 17
C111 MFR-BCT ENG HARN CONN 3 9 C405 AIR FILTER SWITCH 2 9 C500 RH KEY SWITCH 6 12 SW4 HAND/FOOT, H/ISO SWITCH 6 14
C112 HYD OIL FILTER SWITCH 2 11 C406 FUEL SENDER 2 9 C501 A22 PUMP HARN CONN 8 14 SW5 POWER BOBTACH SWITCH 6 17
C113 RIGHT TAILGATE FAN CONN 2 9 C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,12,13, C503 RH DLX PANEL 6 7,12 SW6 BUCKET POSITION SWITCH 6 17
15,17
C114 HAND THROTTLE 6 9 C411 LEFT HANDLE 5 WAY 5 17 C536 A22 PUMP HARN - R SWASH 4 14 SW9 TRAVEL CONTROL SWITCH 6 12
C115 FOOT THROTTLE 6 9 C412 LEFT HANDLE 2 WAY 2 17 C537 A22 PUMP HARN - L SWASH 4 14 SW10 BLOWER SWITCH 5 16
C415 HIGH FLOW SOLENOID 2 17 C542 LEFT SWASH PLATE 3 14 SW11 AC SWITCH 3 16
C118 ENG-CROSSOVER 4 9 C418 FRONT ROD 2 11 C543 RIGHT SWASH PLATE 3 14 SW12 DPF SWITCH 10 12
C119 LEFT TAILGATE FAN CONN 2 9 C419 FRONT BASE 2 11 C544 LEFT FORWARD DRIVE 2 14 T1 BATT GROUND 1 6
C120 ENGINE TEMP SENSOR 2 9 C420 HYD LOCK 2 11 C545 LEFT REVERSE DRIVE 2 14 T2 BUZZER GROUND 1 12
C121 DOSING CONTROL UNIT 94 8,10 C546 RIGHT FORWARD DRIVE 2 14 T3 FLASHER 2 17
C122 SUPPLY MODULE 12 10 C547 RIGHT REVERSE DRIVE 2 14 T4 MEGAFUSE 1 4
C123 HOSE 1 HEATER 2 10 C423 BUCKET POSITION 2 17 C602 LEFT REAR TAIL LIGHT 2 15 T6 BATT GROUND 1 6
C124 HOSE 2 HEATER 2 10 C425 BRAKE SOLENOID 3 11 C603 RIGHT REAR TAIL LIGHT 2 15 T8 BATT GROUND 1 6
C125 HOSE 3 HEATER 2 10 C426 CAN (Remote Start Tool, ACD) 7 7 C606 POWER BOBTACH OPEN 2 17 T10 ENGINE SYSTEM GROUND 1 6
C126 HORN 2 17 C427 TILT ACTUATOR 8 14 C607 POWER BOBTACH CLOSE 2 17 T13 BUZZER POWER 1 12
C129 CAB ACCESSORY 3 13 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,9,13,17 C610 HVAC DUCT FAN 2 16 T14 PRE HEATER 1 9
C155 TANK HEATING VALVE 4 10 C429 LIFT ACTUATOR 8 14 C611 BLOWER MOTOR 4 16 T15 RIGHT REAR WORK LIGHT(+) 1 15
C156 REDUCTION AGENT METERING 2 10 C434-1 LEFT FRONT LIGHT (37W) 2 15 C630 THERMOSTAT 3 16 T16 RIGHT REAR WORK LIGHT(-) 1 15
VALVE
C157 CATALYST TEMP SCR INLET 2 10 C434-2 LEFT FRONT LIGHT (50W) 2 15 C635 HEATER VALVE 6 16 T17 LEFT REAR WORK LIGHT (+) 1 15
C158 CATALYST TEMP SCR OUTLET 2 10 C435-1 RIGHT FRONT LIGHT (37W) 2 15 C667 DOOR HARNESS 6 13 T18 LEFT REAR WORK LIGHT (-) 1 15
C159 ENVIRONMENTAL TEMP 2 10 C435-2 RIGHT FRONT LIGHT (50W) 2 15 C670 EXTERIOR BEACON HARNESS 6 17 T19 BACKUP ALARM 1 14
C160 CATALYST TEMP DOC INLET 2 10 C438 CAB-MFR HARN CONN(DK GRY) 14 13,14,15,16, C676 RADIO 6 17 T20 BACKUP ALARM (GND) 1 14
17
C161 DEF TANK 4 8 C441 TWO SPEED SOLENOID 2 17 FRC1 FUSE RELAY CENTER 112 4,5,9,15,16 T26 FUSE 150 AMP 1 9
C163 NOx PRETREATMENT 5 8 C446 HYDRAULIC FAN SOLENOID 2 11 J1A GATEWAY CONTROLLER 34 5,9,11,12,15 T27 PRE HEATER CONTACTOR PWR 1 9
,16,17
C164 NOx POST TREATMENT 5 8 C449 LEFT JOYSTICK(CAB HARN) 4 7,14 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,11 T29 BATTERY 1 9
12,13,17
C169 ENGINE CAN DIAGNOSTIC 6 8 C450 RIGHT JOYSTICK(CAB HARN) 4 7,14 J2A AUX CONTROLLER 34 11,17 T31 PREHEATER 1 9
C171 INLINE FAN FUSE LEFT 2 9 C459 LEFT HANDLE 4 14 J2B AUX CONTROLLER 26 4,5,6,7,11, T32 ECU CASE GND 1 6
17
C172 INLINE FAN FUSE RIGHT 2 9 C460 RIGHT HANDLE 4 14 J3A ACS CONTROLLER 8 5,6,7,14 T33 DCU CASE GND 1 10
C212 POWER SOCKET 2 13 C474 BRAKE (ROAD KIT) 1 14 J3B ACS CONTROLLER 10 14 T37 DOME LIGHT + 1 13
C252 WASHER ADAPTER INTMD 2 13 C479 LEFT PANEL(BLACK) 12 7,12 J3C ACS CONTROLLER 10 4,6,14 T38 DOME LIGHT - 1 13
C253 WASHER PUMP 2 13 C480 LEFT PANEL(GRAY) 12 12 J5 DRIVE CONTROLLER 48 4,5,6,7,14 T42 PREHEATER FDBK 1 9
C277 AIR RIDE SEAT 6 17 C482 SEATBAR SENSOR 3 13 J7A ENG ECU CONTROLLER (BCT) 58 5,6,8,9

WIRING SCHEMATIC
(SJC MACHINE) Printable Version Click Here
T870 (S/N ASWT11578 - ASWT11946)
(S/N B3BZ11130 - B3BZ11141)
Sheet 1 of 18
Printed In U.S.A. (PRINTED DECEMBER 2016)
7281088
525 of 1052
 J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER)
PIN FUNCTION PIN FUNCTION
PIN FUNCTION PIN FUNCTION A-1 FRONT AUX (F) RETURN (BASE) B-1
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS
A-2 B-2 UNSW BATT
A-2 B-2 UNSW BATT
A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-3 HVAC RELAY - B B-3 UNSW BATT
A-4 RIGHT BLINKER RELAY B-4
A-4 SWITCHED PWR OUT RELAY - A B-4 ENGINE RUN SIGNAL
A-5 HORN RELAY B-5
A-5 FRONT LIGHT RELAY - J B-5
A-6 B-6
A-6 B-6 TRACTION LOCK HOLD
A-7 B-7
A-7 STARTER RELAY - M B-7
A-8 B-8 CAN LO 1
A-8 B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 TAILGATE FANS OUT RELAY - C B-9 CAN HI 1
A-10 B-10
A-10 B-10 HAND THROTTLE
A-11 B-11
A-11 AC SENSE B-11 SEAT BAR
A-12 B-12
A-12 LEFT FAN FDBK RELAY - C B-12 FUEL LEVEL
A-13 B-13 FRONT AUX (F) (BASE)
A-13 B-13 BICS HYD LOCK HOLD
A-14 B-14 CAN HI 2
A-14 B-14 CAN HI 2
A-15 B-15 GROUND
A-15 B-15 GROUND P1
A-16 B-16 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2
A-17 B-17
A-17 REAR LIGHT RELAY - E B-17 GROUND P3, SENSOR
A-18 FRONT AUX (M) RETURN (ROD) B-18
A-18 HYD FAN RETURN B-18 ENGINE TEMP SENSOR
A-19 B-19 FRONT AUX (M) (ROD)
A-19 PTOL LED B-19 HYD FAN OUTPUT
A-20 B-20 CAN LO 2
A-20 PTOL SWITCH B-20 CAN LO 2
A-21 B-21
A-21 SWITCHED PWR FDBK RELAY - A B-21 REMOTE RUN KEY
A-22 B-22 SWITCHED PWR
A-22 STATER FDBK RELAY - M B-22 RUN/ENTER
A-23 B-23
A-23 B-23 SENSOR SUPPLY 8V
A-24 B-24
A-24 START ENGINE B-24 SENSOR SUPPLY 5V
A-25 B-25
A-25 RIGHT FAN FDBK RELAY - C B-25
A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-26 TWO SPEED RETURN B-26 TWO SPEED COIL
A-27
A-27
A-28
A-28 REAR LIGHT FDBK RELAY - E
A-29
A-29
A-30
A-30 HVAC FDBK RELAY - B
A-31
A-31 FRONT LIGHTS FDBK RELAY - K
A-32
A-32 HYD OIL TEMP (8 VOLT)
A-33
A-33 FOOT THROTTLE
A-34
A-34 HYD OIL FILTER SW1

ACS CONTROLLER HARNESS PART NUMBER

CONNECTOR J3A CONNECTOR J3B CONNECTOR J3C EXLF MFR SJC 7281091
PI FUNCTION PIN FUNCTION PIN FUNCTION DLX CAB 7253375
N
DLX FUEL 7266824
A +5V TO SENSORS A A TILT MOTOR 1
BCT ENG 7242470
B SWITCHED POWER B B UNSWITCHED POWER
TAILGATE DOM 7267103
C C C UNSWITCHED POWER Printable Version Click Here
SUSP JSTK 7284703
D CAN HI D D LIFT MOTOR 2
BRAKE ADAPTER 7234968
E CAN LO E TILT ACTUATOR FEEDBACK E
WHL 2 SPD ADP 7159366
WIRING SCHEMATIC
F F F LIFT MOTOR 1
TRACK 2 SPD 7214627
G
H
GROUND
GROUND
G
H LIFT ACTUATOR FEEDBACK
G
H GROUND
(SJC MACHINE)
J
K
J
K
GROUND
TILT MOTOR 2
T870 (S/N ASWT11578 - ASWT11946)
(S/N B3BZ11130 - B3BZ11141)
Sheet 2 of 18
Printed In U.S.A. (PRINTED DECEMBER 2016)
7281088
526 of 1052
 LEGEND
ENGINE CONTROLLER WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX PARTIAL CONNECTOR
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1-3
CONNECTOR J7
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 4-5
PIN FUNCTION
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 6
1 SW POWER BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 7-8
2 GND BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 9-10 CONNECTOR
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 11
3 SW POWER
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 12
4 GND HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB PAGE 13
5 SW POWER CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
CONTROLS PAGE14
6 GND LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 15
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT JOIN ONE WIRE)
9 WATER FUEL SENSOR HVAC PAGE 16
ENGINE 8000 THROUGH 8999 TAN TAN SHEET #
SIGNAL OPTIONS PAGE 17
19 ECU RUN SIGNAL COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
28 MASS AIR FLOW (MAF)
SENSOR FREQUENCY
34 WATER FUEL SENSOR
GROUND
35 MASS AIR FLOW (MAF)
SENSOR TEMP
45 SW POWER SIGNAL
47 ECU CAN 1 LOW
48 ECU CAN 1 HI
56 PREHEATER SIGNAL

Printable Version Click Here

WIRING SCHEMATIC
(SJC MACHINE)
T870 (S/N ASWT11578 - ASWT11946)
(S/N B3BZ11130 - B3BZ11141)
Sheet 3 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A.
7281088

527 of 1052
 UNSWITCHED BATT POWER C408
(BLACK)
1240 RED/WHT
SHEET 12
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400 RED/WHT
SHEET 13
1450 RED/WHT 6 1450 RED/WHT C667 DOOR HARNESS
FRC1 FUSE RELAY CENTER 1420 RED/WHT
SP7 SHEET 12
1110 RED/WHT 2 C500 RH KEY SWITCH
FUSE 11 25 A J1B
1070 RED 1120 RED/WHT 1130 RED/WHT 3 GWY CTRLR 1440 RED/WHT
SHEET 12
SP2 C479 LH PANEL (BLACK)
+12V 1025 RED
FUSE 13 25 A
1160 RED/WHT SP36
1150 RED/WHT 3
J2B
BATTERY MEGAFUSE 1180 RED/WHT 2 AUX CTRLR
100.0 Amps
FUSE 15 25A
1270 RED 1170 RED/WHT SP59 1080 RED/WHT C
J3C
1090 RED/WHT B ACS CTRLR
T4
FUSE 17 25 A
1280 RED 1235 RED/WHT SP58 1260 RED/WHT 48
J5
SHEET 9 1250 RED/WHT 47 DRIVE CTRLR
STARTER
FUSE 4 25 A 1140 RED/WHT
1010 RED SHEET 16
FRC1 HVAC RELAY
1310 RED

FUSE 1 15 A 1320 RED/WHT

SHEET 15
FRC1 REAR LIGHT RELAY
FUSE 2 20 A 1350 RED/WHT SHEET 15
1340 RED
SP26 FRC1 FRONT LIGHT RELAY
1330 RED/WHT
SHEET 15
FRC1 FRONT LIGHT RELAY
FUSE 20 5 A
1335 RED 1345 RED/WHT SHEET 5
FRC1 ENGINE ECU RELAY
FUSE 16 25 A
1325 RED SP1 1300 RED 1035 RED/WHT SHEET 5
FRC 1 ENGINE ECU RELAY
1445 RED/WHT
SHEET 9
FRC1 PRE HEATER RELAY
FUSE 18 25 A
1190 RED 1165 RED/WHT SHEET 7 C426 REMOTE RUN, ACD
1095 RED Printable Version Click Here
1100 RED/WHT SHEET 10
HEATER HOSE RELAY

1220 RED 1230 RED/WHT DCU POWER

WIRING SCHEMATIC
SHEET 10

SHEET 9
1460 RED/WHT C412 LH HANDLE HORN
SHEET 17
(SJC MACHINE)
1045 RED 10 1105 RED/WHT 10

FUSE 22 25 A
TAILGATE FANS RELAY PWR C408 CAB-MFR CONN
(OPTIONS) T870 (S/N ASWT11578 - ASWT11946)
1040 RED 1490 RED/WHT 1410 RED/WHT
SHEET 17
1055 RED
SP60
1290 RED
FUSE 24 25 A
1370 RED/WHT
SP24 (S/N B3BZ11130 - B3BZ11141)
SHEET 13
C408 CAB-MFR CONN
(ACCESSORIES)
Sheet 4 of 18
1050 RED
SHEET 5
FRC1 SWITCHED PWR RELAY (PRINTED DECEMBER 2016)
Printed In U.S.A. 1030 RED
SHEET 9 7281088
FRC1 STARTER RELAY
528 of 1052
 FRC1
1525 RNG SHEET 8
SCR INTERCONNECT
SWITCHED POWER J7A ENGINE ECU
ENGINE ECU
+12V RELAY - G
PWR 1506 RNG/WHT 1
SHEET 4 1035 RED/WHT 30 SP73 SP54
87 1540 RNG/WHT 1545 RNG/WHT 1507 RNG/WHT 3

1509 RNG/WHT 1508 RNG/WHT 5

85 86
8005 TAN 45

FRC1 FUSE RELAY CENTER

SHEET 4 1345 RED/WHT
FUSE 21 15 A
1511 RNG/WHT
SHEET 9 ENG-CROSSOVER

FUSE 5 25 A C489
1780 RNG/WHT A MFR ACCESSORY
FUSE 6 25 A 1850 RNG/WHT
1760 RNG/WHT SHEET 13 C408 CAB-MFR CONN (FR WIPER)
1700 RNG/WHT SHEET 12 SW12 DPF SWITCH
1705 RNG/WHT SHEET 12 SW12 DPF SWITCH
FUSE 12 15 A
1790 RNG/WHT 1550 RNG/WHT 1620 RNG/WHT
SHEET 17 C408 CAB-MFR CONN (BKT POSITION) SHEET 12 C479 LH PANEL (BLACK)
1940 RNG/WHT
SHEET 12 T13 LH PANEL BUZZER
1930 RNG/WHT
SHEET 12 C499 RH PANEL PTOL
1775 RNG/WHT
SHEET 12 SW1 BRAKE SWITCH
C428 1960 RNG/WHT
FUSE 14 5 A J2B (LT GRAY) SHEET 12 SW9 TRAVEL CONTROL SWITCH
1805 RNG/WHT 1560 RNG/WHT 22 1785 RNG/WHT
AUX CTRLR CAB-MFR HARN CONN 2 SHEET 14 SW4 H/ISO SWITCH
1950 RNG/WHT
SHEET 12 C500 RH PANEL KEY SWITCH
1660 RNG/WHT 2 1660 RNG/WHT 1590 RNG/WHT
SHEET 12 C503 RH DELUXE PANEL
FUSE 7 25 A SP42
1765 RNG/WHT SP25 1795 RNG/WHT 1730 RNG/WHT SP65 1735 RNG/WHT
SHEET 7 C426 REMOTE RUN, ACD
FRC1
1725 RNG/WHT
SWITCHED SHEET 8 C169 ENGINE CAN
POWER RELAY - A FUSE 8 25 A
+12V 1580 RNG/WHT
SHEET 13 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
PWR 30 Printable Version Click Here
SHEET 4 1050 RED FUSE 23 15 A
87 1815 RNG/WHT 1800 RNG/WHT

2055 BLK GND 85 86

SHEET 9 ALT EXCITATION
WIRING SCHEMATIC
SHEET 6
3450 LBL 21
J1A C428 (SJC MACHINE)
GWY CTRLR (LT GRAY)
3380 LBL 4 CAB-MFR HARN CONN 2
SP37 SHEET 7
T870 (S/N ASWT11578 - ASWT11946)
1920 RNG/WHT 9 1920 RNG/WHT 1840 RNG/WHT

1830 RNG/WHT
C449 LH JOYSTICK
(S/N B3BZ11130 - B3BZ11141)
SHEET 7

1630 RNG/WHT 50 J5
DRIVE CTRLR
C450 RH JOYSTICK
Sheet 5 of 18
SP52 1650 RNG/WHT B J3A (PRINTED DECEMBER 2016)
1740 RNG/WHT ACS CTRLR

1770 RNG/WHT 7281088

Printed In U.S.A. 1710 RNG/WHT
SHEET 14 C537 A22 PUMP HARN (LH SWASH)
SHEET 14 C536 A22 PUMP HARN (RH SWASH)

529 of 1052
 GROUND
2320 BRN
SHEET 11
C112 HYD OIL FILTER SWITCH
2370 BRN J1B
SHEET 13 GWY CTRLR
C408 CAB-MFR CONN (SEATBAR SENSOR)
2220 BRN SP12 2230 BRN 17
SHEET 11
C108 HYD TEMP SENDER
2190 BRN
2 2001 BLK SHEET 11
C105 HYD CHG PRESSURE SENDER
4 2002 BLK SP53 2820 BLK SP75 2805 BLK 2180 BRN
J7A SHEET 9
ENG ECU CTRLR 6 2003 BLK C355 FUEL HARN (FUEL SENDER)
2150 BRN
SP50 2235 BLK SHEET 9
27 2040 BLK C405 AIR FILTER SWITCH
T32 2004 BLK J5
ECU CASE GND DRIVE CTRLR 28 2490 BLK 2690 BRN
SHEET 9
2880 BLK C408 CAB-MFR CONN (HAND THRTL)
SHEET 10 2695 BRN
SHEET 9
C120 SCR-MFR CONN J3A H 2020 BLK C115 FOOT THROTTLE
ACS CTRLR
2430 BRN 18
2080 BLK SHEET 9
SHEET 7 SP57 ENGINE TEMP GND
C449 LH JOYSTICK H 2270 BLK 2240 BLK T6
2070 BLK J3C BATT GND
SHEET 7 C408 ACS CTRLR J 2260 BLK
C450 RH JOYSTICK (BLACK)
2920 BLK CAB-MFR HARN CONN 1
SHEET 12 2765 BLK
C479 LH PANEL (BLACK) SHEET 15
2940 BLK 2950 BLK 10 2950 BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 12
C499 PTOL 2745 BLK
SP3 SHEET 16
2960 BLK 16 C408 CAB-MFR CONN (HVAC)
SHEET 12 2510 BLK 2110 BLK
C500 RH PANEL KEY SWITCH J1B 2790 BLK T8
GWY CTRLR 15 2500 BLK SHEET 13 BATT GND
2250 BLK C408 CAB-MFR CONN (ACCESSORIES)
SHEET 12
C503 RH DELUXE PANEL 2780 BLK
2065 BLK C428 SHEET 17
SHEET 12 16 C408 CAB-MFR CONN (OPTIONS)
(LT GRAY) 2540 BLK
SW12 DPF SWITCH SP28 2730 BLK
2930 BLK CAB-MFR HARN CONN 2 J2B 15 SHEET 13
SHEET 12 AUX CTRLR 2550 BLK 2090 BLK
SW1 BRAKE SWITCH C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
2830 BLK 2900 BLK 1 2900 BLK
SHEET 17
SW6 BKT POSITION SWITCH
2700 BLK 2770 BLK
SHEET 12 SHEET 17
SW9 TRAVEL CONTROL SWITCH C355 FUEL HARN (PWR BOB/AC)
2785 BLK 2200 BLK
SHEET 17 SHEET 11
C126 HORN C425 BRAKE
2620 BLK
SHEET 15 C103 C489
T16 RH REAR LIGHT B 2720 BLK
TAILGATE HARN MFR ACCESSORY
SHEET 14 2650 BLK SP6
T20 BU ALARM 2600 BLK B 2600 BLK 2390 BLK 10 T1 2015 BLK T10
2640 BLK BATT GND SHEET 9 ENGINE
SHEET 15 2400 BLK 14 ALTERNATOR GROUND GROUND
C602 LH REAR LIGHT SHEET 9
LEFT TAILGATE FANS GND
2610 BLK 2405 BLK 14
SHEET 15 SHEET 9
C603 RH REAR LIGHT RIGHT TAILGATE FANS GND
2630 BLK 2455 BLK
SHEET 15 SHEET 17 Printable Version Click Here
T18 LH REAR LIGHT
C423 BKT POSITION SOLENOID SP27
2710 BLK 2300 BLK
SHEET 7
C426 REMOTE RUN, ACD WIRING SCHEMATIC
SHEET 8 2715 BLK
C169 ENGINE CAN
2290 BLK
(SJC MACHINE)
SHEET 15 2045 BLK SHEET 16
FRC1 REAR LIGHT RELAY D4 COMPRESSOR DIODE
2295 BLK 18
T870 (S/N ASWT11578 - ASWT11946)
SHEET 9
SHEET 15 2115 BLK SP55 TAILGATE FANS RELAY GND 2105 BLK 18 (S/N B3BZ11130 - B3BZ11141)
FRC1 FRONT LIGHT RELAY
SHEET 5
2055 BLK
FRC1 SWITCHED POWER RELAY
Sheet 6 of 18
SHEET 16 2030 BLK
FRC1 HVAC RELAY (PRINTED DECEMBER 2016)
2005 BLK
SHEET 9
FRC1 STARTER RELAY
7281088
Printed In U.S.A. SHEET 15
2120 BLK

FRC1 FRONT LIGHT RELAY

530 of 1052
 CAN BUS
C408
J1B (BLACK)
GWY CTRLR CAB-MFR HARN CONN 1

8 9260 PUR 9230 PUR SP31 9250 PUR SP79 9270 PUR SP19 9220 PUR 4 9220 PUR SP18 9410 PUR SP39 9430 PUR SP35 9450 PUR 9460 PUR 4
CAN LO C479
9 9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
SP30 SP80 SP20 SP17 SP38 SP34 RE019
RE016
120 OHM
120 OHM
0.5 W
0.5 W
RESISTOR
RESISTOR
J5 9440 PUR 4
DRIVE CTRLR C503
9340 PUR/WHT 2 RIGHT DELUXE PANEL
9290 PUR 22
9190 PUR/WHT 12
1830 RNG/WHT 1
SHEET 5 C450
2070 BLK 2
J3A SHEET 6 RIGHT JOYSTICK
ACS CTRLR 9320 PUR/WHT 3 SHEET 14
9420 PUR 4
9240 PUR E
9140 PUR/WHT D
1840 RNG/WHT 1
SHEET 5 C449
2080 BLK 2
SHEET 6 LEFT JOYSTICK
J2B 9300 PUR/WHT 3
SHEET 14
AUX CTRLR 9400 PUR 4
J2B C426
Remote Run Tool, ACD 9280 PUR 8
AUX CTRLR
9180 PUR/WHT 9
14 9500 PUR/WHT A
CAN HI
20 9600 PUR B
CAN LO
Printable Version Click Here

WIRING SCHEMATIC
J1B
GWY CTRLR (SJC MACHINE)
21 3090 LBL D
C
REMOTE RUN KEY T870 (S/N ASWT11578 - ASWT11946)
1735 RNG/WHT E
SHEET 5
SHEET 4
1165 RED/WHT F
SWITCHED POWER
UNSWITCHED POWER
(S/N B3BZ11130 - B3BZ11141)
2710 BLK G
SHEET 6 GROUND
Sheet 7 of 18
Printed In U.S.A. (PRINTED DECEMBER 2016)
7281088

531 of 1052
 J7A
ECU CNTRLR

47
ENGINE CAN BUS SP81 SP90
C121
DOSING CONTROL UNIT

65
9200 PUR 9215 PUR 9415 PUR 9210 PUR SP67 9265 PUR SP71 9275 PUR SP70 9245 PUR
CAN LO 120 Ohm Terminator
48 9100 PUR/WHT 9115 PUR/WHT 9315 PUR/WHT 9110 PUR/WHT SP68 9165 PUR/WHT SP72 9175 PUR/WHT SP69 9145 PUR/WHT 66 Resistor internal to Controller
CAN HI
RE014 SP82 SP91
120 OHM
0.5 W
RESISTOR
J1B
GWY CTRLR C163
NOx PRETREATMENT
9205 PUR 20
9105 PUR/WHT 14 9295 PUR 3
9195 PUR/WHT 4
2835 BLK 2
2875 BLK 5
1

SHEET 10 2870 BLK

NOx GROUND SP78 C164
NOx POST TREATMENT

2815 BLK 2
9285 PUR 3
9185 PUR/WHT 4
5
1635 RNG/WHT 1

1525 RNG 1645 RNG/WHT

SHEET 5
SP76
SCR INTERCONNECT
C161
DEF TANK
1640 RNG/WHT 4
C169
9225 PUR 1
ENGINE CAN
9125 PUR/WHT 2
1 1725 RNG/WHT 3
SHEET 5 SHEET 10 2825 BLK
2 2715 BLK SHEET 6
3 C121
9155 PUR/WHT
DOSING CONTROL UNIT
4 9255 PUR WIRING SCHEMATIC
5 9720 PUR/WHT 82
6 9820 PUR 60
(SJC MACHINE) Printable Version Click Here
T870 (S/N ASWT11578 - ASWT11946)
(S/N B3BZ11130 - B3BZ11141)
Sheet 8 of 18
Printed In U.S.A.
(PRINTED DECEMBER 2016)
7281088

532 of 1052
 1030 RED
FRC1
STARTER
+12V RELAY - M
PWR 30
C111
MFR-BCT HARN CONN
STARTER
ENGINE
SHEET 4 87 8200 TAN A 8220 TAN S M
B SHEET 4
3560 LBL B 3560 LBL R
GND 85 86 8210 TAN C 1015 RED
SHEET 6 2005 BLK 1800 RNG/WHT
FUSE 12
SHEET 5
C115
7 8210 TAN FOOT THROTTLE B
22 D ALTERNATOR G
3560 LBL C405 1800 RNG/WHT
2150 BRN B AIR E
GND EXCITATION
SHEET 6 FILTER
16 3150 LBL A SIG F 2015 BLK
SWITCH SHEET 6
5695 YEL (NC) C +5V PWR
SHEET 13 ENGINE GROUND TERMINAL
J1A 33 3695 LBL A
SIG
GWY CTRLR 2695 BRN B GND FRC1
SHEET 6 TAILGATE FANS FUSE 15 A
25 3105 LBL 18 RELAY - C
12 3100 LBL 18 C119
C104 LEFT TAILGATE
87 A B C171
TAILGATE FANS CONN FAN CONN
TAILGATE FANS RELAY PWR 1105 RED/WHT 10 87A 8110 TAN 14 1 8110 TAN 14 8125 TAN 14 A
LEFT
SHEET 4 30 2 B
TAILGATE 2400 BLK 14 2400 BLK 14
2295 BLK 18 85 86 FANS GND SHEET 6 8105 TAN 14 3 8105 TAN 14
TAILGATE FANS RELAY GND
9 SHEET 6 2405 BLK 14 4 2405 BLK 14
8100 TAN 18 RIGHT FUSE 15 A
TAILGATE SHEET 6 C113
J1B
C355 FANS GND RIGHT TAILGATE
GWY CTRLR FUEL HARN A B C172
C406 FAN CONN
12 3180 LBL C A 8135 TAN 14 A
3180 LBL SIG
FUEL SENDER B
2180 BRN D 2180 BRN B GND
SHEET 6 (30 - 270 OHM)
10 3690 LBL
C428
C120 (LT GRAY)
SHEET 6 ENGINE C114 INTAKE HEATER
2430 BRN 18 2 CAB-MFR HARN CONN 2 +12V CONTACTOR
TEMP HAND THROTTLE
18 T29 PWR FUSE 150 A
3110 LBL 18 1 SENSOR SHEET 13 5690 YEL 7 5690 YEL C 30
+5V PWR 1060 RED 1 2 1065 RED/WHT 87
(950-4400 OHM) 8515 TAN SP77 8500 TAN
3690 LBL 6 A T14
3690 LBL SIG T26 T27
8510 TAN 85 86 1445 RED/WHT
2690 BRN 8 2690 BRN B GND
4 8007 TAN SHEET 4
SHEET 6 D 8505 TAN T31
E
J7A F
ENG ECU CTRLR
8020 TAN SP74
SHEET 10
19 8008 TAN Printable Version Click Here
C100
9 3865 LBL 1 WATER IN FUEL SENSOR
34 2865 BRN 2
SIG
GND (FUEL FILTER) WIRING SCHEMATIC
56
(SJC MACHINE)
C118
28 8013 TAN ENG-CROSSOVER
1
T870 (S/N ASWT11578 - ASWT11946)
35 8014 TAN ENG-CROSSOVER SHEET 5 1511 RNG/WHT
8013 TAN 2 FREQ (S/N B3BZ11130 - B3BZ11141)
8014 TAN 3 TEMP

T42
3420 LBL 4 Sheet 9 of 18
(PRINTED DECEMBER 2016)
7281088
Printed In U.S.A.

533 of 1052
 DOSING CONTROL UNIT HOSE HEATER MAIN
1100 RED/WHT 30
87 8090 TAN
SHEET 4 T33
2975 BLK 85 86
DCU CASE GND

2915 BLK
C121
DOSING CONTROL UNIT

1230 RED/WHT SP62 1245 RED/WHT 5 93 8310 TAN

SHEET 4 1265 RED/WHT 6
C123
1255 RED/WHT 73 67 HOSE 1 HEATER

2310 BRN
1275 RED/WHT 51 68 7998 WHT SP87 8120 TAN 1

89 2
8320 TAN
2880 BLK SP63 2925 BLK 1 90
SHEET 6 7999 WHT
C120 SCR-MFR CONN SHEET 8 2825 BLK 2935 BLK 2 HOSE 1 HEATER
2945 BLK 7 72 SP88 8330 TAN 30
8340 TAN

8140 TAN
87 2955 BLK SP86
Nox Ground 2870 BLK 2855 BLK 29
SHEET 8 C124
2145 BRN 85 86 HOSE 2 HEATER
8020 TAN 22
94 8550 TAN 1
SHEET 9
8240 TAN 2
53 SP85
C155 2135 BRN
1 2170 BRN 75 HOSE 2 HEATER
TANK HEATING VALVE

8150 TAN
4 8540 TAN 92 49 8260 TAN SP89 8250 TAN 30
87 2965 BLK
C156 C125

2985 BLK
85 86 HOSE 3 HEATER
1 8850 WHT 80 2140 BRN
REDUCTION AGENT
50 8560 TAN 1
METERING VALVE 2 8950 BLK 58
2165 BLK 2
59 8350 TAN
C157
1 8900 TAN 83 HOSE 3 HEATER
CATALYST TEMPERATURE
2 2025 BRN 61 27 8370 TAN SP61 8360 TAN
SCR INLET 30
87
C158
1 62 85 86
8520 TAN 2125 BRN
CATALYST TEMPERATURE
SCR OUTLET 2 2160 BRN 84 28 8600 TAN
C159
1 8800 TAN 31 C122 Printable Version Click Here
ENVIRONMENTAL TEMPERATURE SUPPLY MODULE
2 2050 BRN 9
4 1690 RNG/WHT
11
HEATER BATT+ WIRING SCHEMATIC
C160 3 8650 TAN 12

CATALYST TEMPERATURE
1 8530 TAN 18 TXL 34
55 1695 RNG/WHT 3
HEATER SIGNAL

PUMP MOTOR BATT +

(SJC MACHINE)
DOC INLET 2 2075 BRN 18 TXL 12
76 8700 TAN 2
4
PUMP MOTOR CONTROL SIGNAL T870 (S/N ASWT11578 - ASWT11946)
54 2095 BRN PUMP MOTOR GND
77 1680 RNG/WHT 5
PURGING PUMP BATT +
(S/N B3BZ11130 - B3BZ11141)
78 8750 TAN 6
PURGING PUMP SIGNAL Sheet 10 of 18
17 1685 RNG/WHT 10
PRESSURE SENSOR BATT+
39 3000 LBL
9 (PRINTED DECEMBER 2016)
PRESSURE SENSOR SIGNAL
Printed In U.S.A. 40 2085 BRN 8
PRESSURE SENSOR GND 7281088

534 of 1052
 HYDRAULICS
C425

B C308
BRAKE
4200 LGN A 4200 LGN A SOLENOID TRACK 2 SPEED
2200 BLK C 2200 BLK B 9.8 OHM ADAPTER (SEE
SHEET 6 ADDITIONAL
12 V
WHEEL 2 SPD ADP HARNESS 7159366 OPTIONS DWG)
TRACK 2 SPD HARNESS 7214627
TRACK SINGLE SPD BRAKE ADP HARNESS 7234968

C108
2220 BRN B HYDRAULIC
GND
SHEET 6 TEMPERATURE
32 3220 LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320 LBL A SIG HYDRAULIC OIL
GWY CTRLR 2320 BRN B GND FILTER SWITCH (NC)
SHEET 6

C446
18 2910 BRN 2 GND HYDRAULIC
4010 LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410 BRN B GND HYDRAULIC LOCK
4410 LGN A SIG SOLENOID
9.8 OHM 12 V
C105
2190 BRN B GND HYDRAULIC
SHEET 6
3190 LBL C SIG CHARGE
5190 YEL A +8V PWR PRESSURE
0.5-7.5V
4200 LGN

Printable Version Click Here

19 13 1 23 6
J1B
GWY CTRLR
+8V
WIRING SCHEMATIC
C418
(SJC MACHINE)
J2A
AUX CTRLR
18 2330 BRN
4330 LGN
2
1
GND
SIG
FRONT ROD
SOLENOID (MALE)
T870 (S/N ASWT11578 - ASWT11946)
3.3 OHM PWM
C419 (S/N B3BZ11130 - B3BZ11141)
1 2340 BRN 2 GND
4340 LGN 1 SIG
FRONT BASE
SOLENOID (FEMALE) Sheet 11 of 18
3.3 OHM PWM

(PRINTED DECEMBER 2016)

Printed In U.S.A. 19 13 7281088
J2B
AUX CTRLR

535 of 1052
SHEET 5
1940 RNG/WHT
T13
BUZZER (+)

LEFT PANEL
CAB DISPLAY C499
BUZZER Press To Operate Loader
7040 WHT
C479 (PTOL)
T2
LEFT PANEL (BLACK) 1930 RNG/WHT 1
BUZZER (-) SHEET 5 SWITCHED POWER
10 C408 2940 BLK 3
7040 WHT BUZZER SHEET 6 GROUND
(BLACK)
2920 BLK 2 CAB-MFR HARN CONN 1
SHEET 6 GROUND
1960 RNG/WHT 1440 RED/WHT 1
SHEET 5 SHEET 4 UNSWITCHED POWER 20 3030 LBL 1 3030 LBL 2
PTOL OUTPUT
SW9 1620 RNG/WHT 5 SWITCHED POWER
SHEET 5 19 2380 BRN 12 2380 BRN 4
TRAVEL CONTROL PTOL LED
SWITCH (OPTIONAL) 3400 LBL 11 LEFT BLINKER INPUT J1A
SHEET 17
GWY CTRLR
5 6 SHEET 17
3500 LBL 8 C500
RIGHT BLINKER INPUT RIGHT PANEL - KEY SWITCH
4
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 2 8130 TAN 2
SHEET 6 TRAVEL CONTROL INPUT START
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610 LBL 4 5
SHEET 5 1775 RNG/WHT 6
2930 BLK C480 J1B 22 3040 LBL 14 4
SHEET 6 LEFT PANEL (GRAY) 3040 LBL RUN/ENTER SWITCH
GWY CTRLR
3620 LBL 12
SHEET 13 DOOR SIGNAL
11 1950 RNG/WHT 5
SHEET 5 SWITCHED POWER
10 1420 RED/WHT 1
SHEET 4 UNSWITCHED POWER
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
8
SW12
DESOX INHIBIT SWITCH 7 C503
(OPT KIT) 6 RIGHT PANEL DELUXE DISPLAY
1700 RNG/WHT 7 9 8050 TAN 4 1590 RNG/WHT 5
SHEET 5 SHEET 5 SWITCHED POWER
1705 RNG/WHT 10 8 8055 TAN 5
SHEET 5 DESOX INHIBIT LAMP 1240 RED/WHT 1
9 SHEET 4 UNSWITCHED POWER
2065 BLK 2 4 8070 TAN
SHEET 6 DESOX INHIBIT 2250 BLK 3
1 SHEET 6 GROUND
8060 TAN 1 6
3

WIRING SCHEMATIC
Printable Version Click Here
(SJC MACHINE)
T870 (S/N ASWT11578 - ASWT11946)
(S/N B3BZ11130 - B3BZ11141)
Sheet 12 of 18
Printed In U.S.A. (PRINTED DECEMBER 2016)
7281088

536 of 1052
 *
CAB
DLX CAB HARN 7253375 ONLY
C438
(DK GRAY)
CAB-MFR HARN CONN 3 (NOT IN STD CAB HARN)
1850 RNG/WHT 2 1850 RNG/WHT
* C212
POWER
SHEET 5 SOCKET
2795 BLK 1 GND
1375 RED/WHT 2 +12V PWR
C408
(BLACK)
CAB-MFR HARN CONN 1
1370 RED/WHT 7 1370 RED/WHT SP45
*
1390 RED/WHT
T37
DOME LIGHT (+)
SHEET 4
DOME
C129 2010 BLK LIGHT
SP41
CAB ACCESSORY
1210 RED/WHT A +12V BATT PWR * T38
DOME LIGHT (-)
1580 RNG/WHT 5 1580 RNG/WHT SP8 1865 RNG/WHT B +12V SW PWR
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 17
1885 RNG/WHT SHEET 17
SP44 2210 BLK SHEET 17
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 17
2060 BLK SHEET 14
C428
(LT GRAY) * C667
DOOR HARNESS
CAB-MFR HARN CONN 2 (SEE ADDITIONAL
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
WIPER SWITCH, MOTOR SWITCHED POWER
3620 LBL 4
SHEET 12 DOOR SIGNAL
1400 RED/WHT 5
SHEET 4 DOOR UNSW PWR
6
C482 SEATBAR 2840 BLK 2
WIPER MOTOR GROUND
J1B
GWY CTRLR SHEET 6
2370 BRN 4 2370 BRN A GND SENSOR 7310 WHT 3
WASHER SIGNAL

11 3370 LBL 5 3370 LBL B SIG

24 5100 YEL SP13 5370 YEL 3 5370 YEL C +5V PWR

+5V Printable Version Click Here

SHEET 9 5690 YEL

HARNESS WASHER PUMP
7253378
WIRING SCHEMATIC
SHEET 9 5695 YEL
(SJC MACHINE)
* C252 C253
PWR T870 (S/N ASWT11578 - ASWT11946)
A 7310 WHT 1 WASHER

2845 BLK B 2
MOTOR (S/N B3BZ11130 - B3BZ11141)
2845 BLK GND
Sheet 13 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7281088
537 of 1052
 CONTROLS
SW4 J5
HAND/FOOT DRIVE CTRLR
(ACS)
H/ISO 33
(SJC, AWS) 34
SWITCH
SHEET 5
1785 RNG/WHT 2 1
3 40 5890 YEL SP11
+5V
SHEET 13 2060 BLK 5 6
4
C438 23
J5 (DK GRAY) 24
DRIVE CTRLR CAB-MFR HARN CONN 3

6 4235 LGN 7 4235 LGN C536

5810 YEL 2 C543 A22 PUMP HARNESS
16 4275 LGN 8 4275 LGN
29 SP56 2810 BRN 4 2810 BRN 1
4 9 4550 LGN 2890 BRN GND
RIGHT
4550 LGN 8 3 3810 LBL 3
3810 LBL SIG SWASHPLATE
1710 RNG/WHT 1 1710 RNG/WHT 2 +12V PWR
SHEET 5
C103 C537
TAILGATE HARN 5860 YEL 2 C542
T19 TERMINAL (+)
36 7100 WHT C 7100 WHT 2860 BRN 4 2860 BRN 1 GND LEFT
BACK UP 7 3860 LBL 3 3860 LBL 3 SIG SWASHPLATE
2650 BLK ALARM 1770 RNG/WHT 1 1770 RNG/WHT 2 +12V PWR
SHEET 6 SHEET 5
T20 TERMINAL (-) C501 C546
43 4260 LGN 1 4260 LGN 1
RIGHT FORWARD DRIVE
42 2660 BRN 2 2660 BRN 2
C460
1 1830 RNG/WHT 1 +12V PWR
C547
C450 2 2070 BLK 2 GND 44 3 4250 LGN 1
RIGHT JOYSTICK
RIGHT 4250 LGN
RIGHT REVERSE DRIVE
3 9560 PUR/WHT 3 CAN HI 45 2650 BRN 4 2650 BRN 2
HANDLE
4 9660 PUR 4 CAN LO
C545
31 4280 LGN 5 4280 LGN 1
C459 41 2680 BRN 6 2680 BRN 2 LEFT REVERSE DRIVE
1 1840 RNG/WHT 1 +12V PWR

C449 2 2080 BLK 2 GND C544

LEFT JOYSTICK 3 9540 PUR/WHT 3 CAN HI
LEFT 21 4270 LGN 7 4270 LGN 1
11 8 2670 BRN 2 LEFT FORWARD DRIVE
HANDLE 2670 BRN
4 9640 PUR 4 CAN LO

SUSP SEAT JOYSTICK HARNESS 7163706 C474

C429 26 4210 LGN A BRAKE CONN
LIFT ACTUATOR USED WITH ROADLIGHT KIT
4600 LGN 5 76 LGN
6
4610 LGN 8 77 LGN
7
Printable Version Click Here
G 2970 BRN SP5 2980 BRN 1 45 LGN GND
J3A
ACS CTRLR
A 5970 YEL SP29 5980 YEL
4
3 79 LGN +5V PWR
WIRING SCHEMATIC
+5V
J3B
ACS CTRLR
3980 LBL 2 78 LGN SIG (SJC MACHINE)
H
E
C427
2
TILT ACTUATOR T870 (S/N ASWT11578 - ASWT11946)
J3C 3990 LBL 81 LGN SIG
ACS CTRLR
5990 YEL
4
3 80 LGN +5V PWR
(S/N B3BZ11130 - B3BZ11141)
F
6
D 2990 BRN 1 46 LGN GND Sheet 14 of 18
A 4640 LGN 5 82 LGN
7 (PRINTED DECEMBER 2016)
K 4650 LGN 8 83 LGN
7281088
Printed In U.S.A.
538 of 1052
 C434-1
2735 BLK B GND LEFT FRONT
C408
6100 PNK A SIG WORK LIGHT

LIGHTS
(BLACK)
CAB-MFR HARN CONN 1 37.00 Watts
C434-2
2765 BLK 9 2765 BLK SP14 2750 BLK B GND
SHEET 6 LEFT FRONT
6110 PNK A SIG WORK LIGHT
50.00 Watts

C435-1
8 6000 PNK SP15 6120 PNK A SIG RIGHT FRONT
RC1 WORK LIGHT
2760 BLK B GND
FRONT WORK 37.00 Watts
LIGHTS RELAY - 1
C438 C435-2
(DK GRAY) 6130 PNK A SIG
SHEET 4 1350 RED/WHT 30 CAB-MFR HARN CONN 3 RIGHT FRONT
87 6620 PNK SP23 6610 PNK 2705 BLK B GND WORK LIGHT
50.00 Watts
13 6610 PNK SP64
SHEET 6 2120 BLK 85 86

6630 PNK

6000 PNK
RC2
FRONT WORK
LIGHTS RELAY - 2 C103
+12V TAILGATE HARN C603
PWR 2610 BLK 2 GND
1330 RED/WHT 30 SHEET 6 RIGHT REAR
SHEET 4 87 6340 PNK SP10 6310 PNK A 6310 PNK 6320 PNK 1 SIG
TAIL LIGHT
SP49
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A Printable Version Click Here
17 6210 PNK
GWY CTRLR
28 3440 LBL
WIRING SCHEMATIC
SHEET 6
2620 BLK
T16 TERMINAL (-)
GND RIGHT REAR
(SJC MACHINE)
SIG WORK LIGHT
FRC1
REAR LIGHT
6210 PNK
T15 TERMINAL (+)
T870 (S/N ASWT11578 - ASWT11946
1320 RED/WHT
+12V RELAY - E
PWR 30 T17 TERMINAL (+)
(S/N B3BZ11130 - B3BZ11141)
SHEET 4 87 6200 PNK H 6200 PNK SP96 6220 PNK SIG LEFT REAR
GND 85 86 SHEET 6
2630 BLK GND WORK LIGHT Sheet 15 of 18
2045 BLK
SHEET 6 T18 TERMINAL (-)
(PRINTED DECEMBER 2016)
Printed In U.S.A.
7281088

539 of 1052
 2440 BLK * C610
2 GND HVAC DUCT

HVAC
7440 WHT 1 SIG FAN

2560 BLK
* C483
C BLK
7420 WHT A DBL POTENTIOMETER
(TEMP CONTROL
* DLX CAB HARN 7253375 ONLY 7425 WHT B WHT SWITCH)

(NOT IN STD CAB HARN) * C635

D SIG
2130 BLK C GND HEATER
7430 WHT A +12V PWR VALVE
SP48 B
E
F

FRC1
HVAC
C438
(DK GRAY)
*BLOWER
SW10

+12V RELAY - B CAB-MFR HARN CONN 3 SWITCH

PWR 30 OFF
1140 RED/WHT
SHEET 4 87 1500 RNG/WHT 10 1500 RNG/WHT 5 2
1
2030 BLK GND 85 86 4
SHEET 6 7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
3 7520 WHT 2 7.50 Amps Med BLOWER
7050 WHT MOTOR
SW11 7510 WHT 3 5.00 Amps Low
J1A
30 3050 LBL
SHEET 6
2745 BLK 11 2745 BLK *
AC SWITCH 2580 BLK 4
GWY CTRLR SP16
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT SP40 7020 WHT 12
C630
* 3
THERMOSTAT Printable Version Click Here
AC EVAPORATOR
SWITCH
C350
B 7023 WHT
2570 BLK
7020 WHT
2
1 WIRING SCHEMATIC
A 7024 WHT
(SJC MACHINE)
C486
7025 WHT 1
2
SIG
GND
MAGNET CLUTCH T870 (S/N ASWT11578 - ASWT11946)
(COMPRESSOR)
SHEET 6
2290 BLK
D4
2280 BLK
(S/N B3BZ11130 - B3BZ11141)
Sheet 16 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7281088

540 of 1052
 C355
C428
(LT GRAY) #
OPTIONS
# C607
FUEL HARN CAB-MFR HARN CONN 2 DLX FUEL HARN 7266824 ONLY
POWER BOB
SIG
GND
1
2
4470 LGN
2470 BLK 2770 BLK
E
B
4470 LGN
2770 BLK
11 4470 LGN
4480 LGN
(NOT IN STD FUEL HARN 7149219)
CLOSE SHEET 6
SW5
*POWER 2 1
* DLX CAB HARN 7253375 ONLY
# C606 BOBTACH 3
SWITCH 5 4
2 2480 BLK
POWER BOB
OPEN
GND
SIG 1 4480 LGN F 4480 LGN 10
6
(NOT IN STD CAB HARN)
6010 PNK 13 6010 PNK

1380 RED/WHT
1550 RNG/WHT 12 1550 RNG/WHT
SHEET 5

C438
(DK GRAY)
CAB-MFR HARN CONN 3 1200 RED/WHT
SP43
C411
B
SHEET 4
1410 RED/WHT 1 1410 RED/WHT 1430 RED/WHT X
L
* FLASHER
T3

LEFT HANDLE CONN

C SHEET 12 3500 LBL
(FLASHER) 5 WAY SP21 D1
A 6515 PNK 6500 PNK 6 6500 PNK 6530 PNK
*BEACON
SW2

6570 PNK
(SEE ADDITIONAL E
OPTIONS DWG) D 6415 PNK SP22 6400 PNK 3 6400 PNK
D2 6430 PNK SWITCH
3400 LBL 2725 BLK 6
C103 SHEET 12 *HAZARD
SW3
2
1
6700 PNK
4
1
5
2
TAILGATE HARN 3
SWITCH 4 3
5
EURO TAIL LIGHTS E 6410 PNK (PINS 3 & 6 2850 BLK SP46
INTERNALLY 6
D
(SEE ADDITIONAL
OPTIONS DWG)
6510 PNK
INSULATED) * C670E
2780 BLK 4 2780 BLK 2780 BLK 2420 BLK D
C423 SHEET 6 BEACON/FLASHER
3 6440 PNK F EXTERIOR HARNESS
BUCKET SIG A 4450 LGN D3 4455 LGN 5 4455 LGN 1
4
2 *BUCKET
SW6
6540 PNK B (SEE ADDITIONAL
OPTIONS DWG)
POSITION 2830 BLK 5 POSITION C
SOLENOID GND B 2450 BLK 2455 BLK SHEET 6 SWITCH A
SHEET 6 6
9.8 OHM
C408
(BLACK) * C676

LEFT HANDLE C412

CAB-MFR HARN CONN 1 SHEET 6
2785 BLK
C126
B GND LEFT
*+ C279
1 7820 WHT
RADIO CONN
3
C277
(HORN) 2 WAY
(SEE ADDITIONAL
B
A 1460 RED/WHT
7210 WHT 13 7210 WHT A SIG HORN SPEAKER
-
2 7830 WHT 4
* 1
OPTIONS DWG) SHEET 4 2
C497
SJC
RIGHT
*- C278
2 7810 WHT 6 3
AIR RIDE
SEAT
5 7200 WHT C SPEAKER 1 7800 WHT 5 1510 RNG/WHT 4 PWR
HORN/BLINKER SHEET 13
4 6420 PNK A + 1 2210 BLK 5 GND
(SEE ADDITIONAL 1885 RNG/WHT SHEET 13
3 6520 PNK B SHEET 13 6
J2A OPTIONS DWG) 2885 BLK 2
SHEET 13
AUX CTRLR
C415
26 B GND HIGH FLOW Printable Version Click Here
2460 BRN
SOLENOID
4460 LGN A SIG
7.5 OHM 12 V WIRING SCHEMATIC
J2B 26
AUX CTRLR
(SJC MACHINE)
C441
J1A 26 2350 BRN 2 GND TWO SPEED TRACK 2 SPEED
ADAPTER
T870 (S/N ASWT11578 - ASWT11946)
GWY CTRLR 4350 LGN 1 SIG SOLENOID
5.1 OHM 12 V (SEE ADDITIONAL
OPTIONS DWG) (S/N B3BZ11130 - B3BZ11141)
J1B 26
GWY CTRLR
Sheet 17 of 18
Printed In U.S.A. (PRINTED DECEMBER 2016)
7281088
541 of 1052
 T14 PRE HEATER 179 J7B
PRE HEATER C130

ENGINE
ENG ECU CTRLR 105 TEMP SENSOR 1
C153 EXHAUST GAS
(DOOSAN HARNESS)
1 122 TEMP SENSOR
SENSOR RETURN 1
WASTE GATE BEFORE DPF
2 186
C131
C152 106 TEMP SENSOR 2 EXHAUST GAS
1 POSITION SENSOR 161 123 TEMP SENSOR
SENSOR RETURN 2
WASTE GATE BEFORE TURBINE
113

SUPPLIED
2 POSITION FEEDBACK
POSITION C132
3 POSITION GND 121 107 TEMP SENSOR 3 EXHAUST GAS
124 TEMP SENSOR
C151 SENSOR RETURN 3
BEFORE DOC
1 EGR VREF3 164
C133
5 POSITION SIGNAL 116 194 TEMP SENSOR 4 EXHAUST GAS
EGR VALVE
3 172 169 TEMP SENSOR
DC MOTOR POSITION RETURN SENSOR RETURN 4
AFTER DPF
6 H BRIDGE POS 192
C134
2 H BRIDGE NEG 193 166 VREF2 EG DPS 1
C150 108 PRESSURE SENSOR 3 EXHAUST GAS
AIR SENSOR 114 144 2 PRESSURE SENSOR
AMBIENT AIR SENSOR RETURN
TEMP SENSOR AIR RETURN 171
C135
C149 184 H BRIDGE POS 5
1 COOLANT TEMP SENSOR 109
COOLANT TEMP 183 H BRIDGE NEG 4 INTAKE
SENSOR 2 COOLANT RETURN 145 THROTTLE
163 VREF 3 THROTTLE POSITION 1
C148 170 POSITION SENSOR GND 3
1 FUEL TEMP SENSOR 110 115 2
FUEL TEMP POSITION FEEDBACK ANALOG
SENSOR 2 FUEL RETURN 146 185 GLOW PLUG RELAY DRIVER C136
C147 165 VREF3 OIL PRESSURE
1 131 OIL PRESSURE &
ENGINE BLOCK SENSOR SIGNAL 111 OIL PRESSURE SENSOR TEMPERATURE
ACCELEROMETER 1 2 SENSOR RETURN 130 148 RETURN GND SENSOR
SHIELD 128
104 OIL TEMPERATURE SENSOR
C146
1 132 C137
SENSOR SIGNAL
ENGINE BLOCK 156 UN 6
ACCELEROMETER 2 2 SENSOR RETURN 133 O2 SENSOR
SHIELD 129 157 VM 2 & HEATER
154 IA 5
C145 155 1
160 IP
CRANK SENSOR POS SHEET ?
VR CRANK 182 O2 HEATER 3
SENSOR CRANK SENSOR NEG 136
4
C144
C138
1 SENSOR RETURN 147
141 VREF2 INTAKE PRESS B Printable Version Click Here
CAM SHAFT 2 159
POS SENSOR 112 A
SENSOR
3 VREF1 CAM 140
167
INTAKE PRESS SENSOR
INTAKE PRESS RETURN D
INLET TEMP
PRESSURE
WIRING SCHEMATIC
SENSOR
C143
1 RAIL PRESSURE SENSOR 135
134
168
INTAKE AIR TEMP SENSOR
INTAKE AIR TEMP RETURN
C
E
(SJC MACHINE)
RAIL PRESSURE 119
SENSOR
2
3
SENSOR RETURN
VREF 1 SENSOR 138 C139 T870 (S/N ASWT11578 - ASWT11946)
127 FUEL INJECTOR HSDA
C141
151
126 FUEL INJECTOR LSD1A CYL 1 (S/N B3BZ11130 - B3BZ11141)
FUEL INJECTOR HSDB
CYL 3
FUEL INJECTOR LSD1B 175
150 FUEL INJECTOR HSDB
C140
Sheet 18 of 18
C142 174 CYL 2
FUEL INJECTOR LSD2B
FUEL INJECTOR HSDA 103 (PRINTED DECEMBER 2016)
CYL 4 125 C154
FUEL INJECTOR LSD2A
Printed In U.S.A. 177 PWM 2 7281088
INLET METERING
1 VALVE

542 of 1052
 Index Diagram
1 SH01 - INDEX
2 SH02 - UNSWITCHED BATT POWER
3 SH03 - SWITCHED POWER WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
4 SH04 - GROUND
5 SH05 - CAN BUS GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
6 SH06 - ENGINE CAN BUS
7 SH07 - ENGINE BATT FEED, GENERAL 1000 THROUGH 1499 RED RED LEGEND
8 SH08 - ENGINE CONTROLLER UNIT
9 SH09 - DOSING CONTROL UNIT BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT CONNECTOR
10 SH10 - HYDRAULICS
11 SH11 - CAB DISPLAY BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT 1 1
12 SH12 - CAB
13 SH13 - CONTROLS BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
14 SH14 - LIGHTS PARTIAL CONNECTOR
15 SH15 - HVAC
CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN
16 SH16 - OPTIONS 1 1 1
17 SH17 - OPTIONS 2
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
1 1
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN

WIRE BREAK
HARNESS PART NUMBER CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL
SHT1/F2
WIRE BREAK
SHT1/F2
EXLF MFR SJC 7300861 WIRE BREAK
LIGHTS 6000 THROUGH 6999 PINK PNK SHT1/F2 SHT1/F2
DLX CAB 7301237
DLX FUEL 7266824 OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
BCT ENG 7242470
ENGINE 8000 THROUGH 8999 TAN TAN
TAILGATE DOM 7267103
SUSP JSTK 7284703 COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
WHL 2 SPD ADP 7159366
COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT
TRACK 2 SPD 7214627
DEF JUMPER 7305995

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
Click Here For Interactive PDF S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 1 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
REVISED C161 PIN ASSIGMENTS
DESCRIPTION
103427 MPS
CHG NOTICE DWN
6
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 1 / 17
7300861
Printable Version Click Here
543 of 1052
 UNSWITCHED
BATT POWER
1240 RED/WHT
SHT11/E4
1400 RED/WHT
C408 SHT12/D3
1450 RED/WHT 1450 RED/WHT SP7
6 6
1420 RED/WHT
SHT11/E4
FUSE RELAY CENTER
1440 RED/WHT
1110 RED/WHT SHT11/G8
2
FUSE 11 25 A GATEWAY CTRLR
1070 RED 1120 RED/WHT 1130 RED/WHT
11A 11B 3
SP2
FUSE 13 25 A SP36 J1B
1025 RED 1160 RED/WHT 1150 RED/WHT
13A 13B 3
AUX CTRLR
1180 RED/WHT
2
J2B
+12V BATTERY MEGAFUSE
100.0 Amps FUSE 15 25A
HW11 1 1 1270 RED 1170 RED/WHT SP59 1080 RED/WHT
15A 15B C
T5 T4
ACS CTRLR
1090 RED/WHT
B
FUSE 17 25 A J3C
1280 RED 1235 RED/WHT SP58 1250 RED/WHT
17A 17B 2
1260 RED/WHT DRIVE CTRLR

1010 RED
3
SHT7/G1
FUSE 4 25 A J5B
1310 RED 1140 RED/WHT
4A 4B SHT15/E8

FUSE 1 15 A
1320 RED/WHT
1A 1B SHT14/B8

BUS BAR
FUSE 2 20 A
SP26 1340 RED 1330 RED/WHT
2A 2B SHT14/D8

1350 RED/WHT

1325 RED
FUSE 20 5 A SHT14/F8
1335 RED 1345 RED/WHT
20A 20B SHT3/G8

FUSE 16 25 A
SP1 1300 RED 1035 RED/WHT
16A 16B SHT3/H8

1445 RED/WHT
SHT7/B3
FUSE 18 25 A
1190 RED 1165 RED/WHT
18A 18B SHT5/B8
1055 RED

FUSE 25 10A
1095 RED 1100 RED/WHT
25A 25B SHT9/H8

FUSE 26 15A
1220 RED 1230 RED/WHT
26A 26B SHT9/G8

FUSE 10 30A
1045 RED 1105 RED/WHT
10A 10B SHT7/E7

1460 RED/WHT
SHT16/B7
FUSE 22 25 A
1040 RED 1490 RED/WHT 1410 RED/WHT
22A 22B SHT16/F7
SP24

FUSE 24 25 A
SP60 1290 RED 1370 RED/WHT
24A 24B SHT12/F8

FRC1 FRC1
1050 RED
SHT3/D8
1030 RED
SHT7/H8

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 2 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427 MPS
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 2 / 17
7300861
Printable Version Click Here
544 of 1052
 FRC1 ENGINE 1525 RNG/WHT
SHT6/E4
ECU RELAY - G

1035 RED/WHT +12V PWR 30

1506 RNG/WHT
1 SWITCHED
SHT2/D1 G1 87 1540 RNG/WHT 1545 RNG/WHT SP54 1507 RNG/WHT

86 85
G4
SP73
1508 RNG/WHT
3

ENG ECU CTRLR

POWER
G2 G5 5

FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/D1 J7A
FUSE RELAY CENTER

FUSE 21 15 A
1509 RNG/WHT 1511 RNG/WHT
21A 21B SHT7/B7

FUSE 5 25 A
1780 RNG/WHT C489
5A 5B A A MFR ACCESSORY

BUS BAR
FUSE 6 25 A
1760 RNG/WHT 1850 RNG/WHT
6A 6B SHT12/G8
1575 RNG/WHT
SHT17/G4
FUSE 12 25 A
1790 RNG/WHT 1550 RNG/WHT
12A 12B SHT16/G7

1700 RNG/WHT
SHT11/C8
1705 RNG/WHT
SHT11/B8
1620 RNG/WHT
SHT11/G8
1940 RNG/WHT
SHT11/H8
1930 RNG/WHT
FUSE 14 5 A SHT11/H4
1805 RNG/WHT 1560 RNG/WHT 1775 RNG/WHT
14A 14B 22 AUX CTRLR SHT11/D8
1960 RNG/WHT
J2B SHT11/F8
FRC1 C428 1785 RNG/WHT
SWITCHED SHT13/H8
MFR HARN CONN 2
POWER 1950 RNG/WHT
(LT GRAY) SHT11/F4
RELAY - A 1660 RNG/WHT 1660 RNG/WHT 1590 RNG/WHT
2 2 SHT11/E4
SP42 1565 RNG/WHT
SHT17/E4
+12V PWR
1050 RED 30 FUSE 7 25 A SP65
SHT2/B1 A1 87 1765 RNG/WHT SP25 1795 RNG/WHT 1730 RNG/WHT 1735 RNG/WHT
A4 7A 7B SHT5/B8
GND
86 85

BUS BAR
A5 A2 1725 RNG/WHT
SHT6/D7
FRC1 FRC1 FUSE 8 25 A
1580 RNG/WHT
8A 8B SHT12/F8

FUSE 23 15 A
1815 RNG/WHT 1800 RNG/WHT
23A 23B SHT7/G8

FRC1 FRC1
2055 BLK
SHT4/B8

GATEWAY CTRLR
C428
3450 LBL SP37
21 SWITCHED POWER RELAY FEEDBACK 1920 RNG/WHT 1920 RNG/WHT 1840 RNG/WHT
9 9 SHT5/E3
1830 RNG/WHT
3380 LBL SHT5/E3
4 SWITCHED POWER RELAY SIGNAL

J1A 1630 RNG/WHT

21 DRIVE CTRLR
1740 RNG/WHT SP57
J5B
1650 RNG/WHT
B ACS CTRLR
J3A
1770 RNG/WHT
SHT13/F2
1710 RNG/WHT
SHT13/F2

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 3 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 3 / 17
7300861
Printable Version Click Here
545 of 1052
 ENG ECU CTRLR

2
2001 BLK GROUND
SP53 SP75
2002 BLK 2820 BLK 2805 BLK
4
2035 BLK 2320 BRN
2003 BLK 15 SP50 2235 BLK SHT10/F7 GATEWAY CTRLR
6 DRIVE CTRLR 2370 BRN
2490 BLK SHT12/D8
T32 J7A 16 2220 BRN SP12 2230 BRN
2004 BLK
ECU CASE GND SHT10/G7 17 SENSOR GND
1 2155 BLK
J5B 2190 BRN
SHT17/F4 SHT10/E7
2195 BLK
J1B
2880 BLK 2180 BRN
SHT9/F8 H SHT7/D7
2150 BRN
J3A SHT7/G7
ACS CTRLR 2270 BLK SP66 2240 BLK 2695 BRN
2080 BLK H SHT7/F7
SHT5/D3 2430 BRN
2260 BLK SHT7/C7
2070 BLK J
SHT5/E3
J3C T6
2920 BLK 1 BATT GND
SHT11/G8 C408
MFR HARN CONN 1 (BLACK)
2940 BLK SP4 2950 BLK 2950 BLK
SHT11/G4 10 10

2960 BLK
SHT11/E4
GATEWAY CTRLR
2250 BLK 2510 BLK SP3 2110 BLK
SHT11/D4 16
2500 BLK
15
2765 BLK
SHT14/H8
J1B
2745 BLK
SHT15/D7
T8
2790 BLK 1 BATT GND
2540 BLK SHT12/D8
2860 BLK 16
SHT17/D4
AUX CTRLR SHT16/E7
2780 BLK
2890 BLK 2550 BLK 2090 BLK
SHT17/H4 15
2065 BLK SP28 2730 BLK
SHT11/C8 J2B SHT12/E8
2930 BLK C428
SHT11/E8 MFR HARN CONN 2 (LT GRAY)
2830 BLK 2900 BLK 2900 BLK
SHT16/D5 1 1
2700 BLK SP47
SHT11/F8
2785 BLK 2770 BLK
SHT16/B7 SHT16/H6 T10
SHT7/F3
2015 BLK 1
ENGINE GROUND
2200 BLK
SHT10/F4

2620 BLK C489 2720 BLK

SHT14/C4 MFR ACCESSORY B B

2650 BLK
SHT13/F8 C103
TAILGATE HARN T1
2640 BLK 2600 BLK 2600 BLK SP6 2390 BLK BATT GND
SHT14/C4 B B 1
SP51
2610 BLK
SHT14/E4 2400 BLK
SHT7/E4
2630 BLK
SHT14/B4 2405 BLK AUX CTRLR
SHT7/D4

2185 BRN
2455 BLK SHT17/D7 17 SENSOR GND
SHT16/D6

2710 BLK SP27 2300 BLK J2B

SHT5/B8

2715 BLK
SHT6/D7

2290 BLK
SHT15/B8
2505 BLK
SHT17/G4
2045 BLK 2295 BLK
SHT14/B8 SHT7/D7
2115 BLK
SHT14/D8
2055 BLK
SP55 2105 BLK
SHT3/C1
2030 BLK
SHT15/F8
2005 BLK
SHT7/G7
2120 BLK
SHT14/E8

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 4 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427 MPS
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 4 / 17
7300861
Printable Version Click Here
546 of 1052
 CAN BUS
* DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)

RE016 RE019 C479

C408
120 OHM 0.5 W RESISTOR MFR HARN CONN 1 (BLACK) 120 OHM 0.5 W RESISTOR LEFT PANEL
GATEWAY CTRLR R3-1 SP19 SP18 (BLACK)
TP-09 9260 PUR TP-09 TP-10 9230 PUR TP-10 SP31 TP-12 TP-12 SP79 TP-14 9270 PUR TP-16 9220 PUR TP-16 TP-01 TP-01 TP-03
SP39 TP-05 TP-05 SP35 TP-07 TP-07 R1 TP-08
9250 PUR TP-14 9220 PUR TP-03 9410 PUR 9430 PUR 9450 PUR 9460 PUR TP-08
CAN LO 8 4 4 4 CAN LO

SP30 SP80 SP17 SP38 SP34

9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9170 PUR/WHT 9120 PUR/WHT 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT
CAN HI 9 3 3 3 CAN HI
R3-2 SP20 TP-15 R2
TP-13 TP-02 TP-04 TP-06
J1B
C479

C503
RH DLX PANEL
DRIVE CTRLR 9440 PUR TP-06
9290 PUR TP-15 4 CAN LO
8 CAN LO
9190 PUR/WHT 9340 PUR/WHT
9 CAN HI 2 CAN HI
TP-11
J5B
C503
ACS CTRLR
9240 PUR TP-13
E CAN LO * C450 C460
RIGHT JOYSTICK
RIGHT JOYSTICK CONN RIGHT JOYSTICK
9140 PUR/WHT 1830 RNG/WHT 1830 RNG/WHT +12V PWR
D CAN HI SHT3/B1 1 1 1 1
2070 BLK 2070 BLK GND
J3A SHT4/G8 2 2 2 2
9320 PUR/WHT TP-04 9560 PUR/WHT CAN HI
3 3 3 3
AUX CTRLR 9420 PUR 9660 PUR CAN LO
4 4 4 4
TP-11
9280 PUR
8 CAN LO

9180 PUR/WHT
9 CAN HI * C449 C459
LEFT JOYSTICK
LEFT JOYSTICK CONN LEFT JOYSTICK
J2B 1840 RNG/WHT 1840 RNG/WHT +12V PWR
SHT3/C1 1 1 1 1
2080 BLK 2080 BLK GND
SHT4/G8 2 2 2 2
9300 PUR/WHT TP-02 9540 PUR/WHT CAN HI
3 3 3 3
9400 PUR 9640 PUR CAN LO
4 4 4 4
SUSP SEAT JOYSTICK HARNESS

AUX CTRLR C426

Remote Run Tool, ACD
TP-30 9500 PUR/WHT TP-30
CAN HI 14 A A CAN HI

9600 PUR
CAN LO 20 B B CAN LO

J2B
3095 LBL
REMOTE RUN KEY 24
J2A
GATEWAY CTRLR

3090 LBL 3085 LBL REMOTE RUN KEY

REMOTE RUN KEY 21 D D
SP93

J1B
C C

1735 RNG/WHT SWITCHED POWER

SHT3/D1 E E

1165 RED/WHT UNSWITCHED POWER

SHT2/D1 F F

2710 BLK GROUND

SHT4/C6 G G

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 5 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 5 / 17
7300861
Printable Version Click Here
547 of 1052
 ENGINE
CAN BUS
RE014
120 OHM 0.5 W RESISTOR 120 Ohm Terminator DOSING CONTROL UNIT
R5-1 Resistor internal to
ENG ECU CTRLR SP81 SP90
TP-17 TP-17 TP-18 TP-18 TP-20 TP-22 9210 PUR TP-22 SP67 TP-24 TP-24 SP71 TP-26 TP-26 SP70 TP-28 Controller TP-28
9200 PUR 9215 PUR 9415 PUR TP-20 9265 PUR 9275 PUR 9245 PUR
ENG CAN LO 47 65 ENG CAN LO

SP82 SP91 SP68 SP72 SP69

9100 PUR/WHT 9115 PUR/WHT 9315 PUR/WHT 9110 PUR/WHT 9165 PUR/WHT 9175 PUR/WHT 9145 PUR/WHT
ENG CAN HI 48 66 ENG CAN HI
R5-2
J7A C121
TP-19 TP-21 TP-23 TP-25 TP-27

9105 PUR/WHT
C163

9205 PUR
NOx PRETREATMENT
1645 RNG/WHT
1
2835 BLK
2
9295 PUR TP-27
3
9195 PUR/WHT
GATEWAY CTRLR 4
2870 BLK 2875 BLK
TP-19 SHT9/F8 5
20 ENG CAN LO SP78
C163

14 ENG CAN HI
C164
J1B
NOx POST TREATMENT
1635 RNG/WHT
1
2815 BLK
2
TP-25
9285 PUR
3
9185 PUR/WHT
4
5

C164
1525 RNG/WHT
SHT3/H1 SP76

C162 C161
B
DEF JUMPER CONN DEF TANK
C169 1640 RNG/WHT 1640 RNG/WHT
4 4 1
ENGINE CAN 9225 PUR TP-23 TP-31
9225 PUR
TP-31
1 1 4 ENG CAN LO
1725 RNG/WHT 9125 PUR/WHT 9125 PUR/WHT
1 SHT3/D1 2 2 3 ENG CAN HI
2825 BLK 2825 BLK
SHT9/F8 3 3 2
2715 BLK
2 SHT4/C6 C161
HARNESS DEF JUMPER

TP-21 9155 PUR/WHT

ENG CAN HI 3

9255 PUR
ENG CAN HI 4
DOSING CONTROL UNIT

TP-29 TP-29
9720 PUR/WHT
CAN HI DCU DIAGNOSTIC 5 82 CAN HI DCU DIAGNOSTIC

CAN LO DCU DIAGNOSTIC 9820 PUR

6 60 CAN LO DCU DIAGNOSTIC

C169
C121

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 6 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 6 / 17
7300861
Printable Version Click Here
548 of 1052
 T7 STARTER
FRC1 STARTER
RELAY - M
1
1
R ENGINE
C111
1030 RED MFR-BCT HARN CONN T21 S
SHT2/A1 M1 87 8200 TAN 8220 TAN
30 M4 A A

8210 TAN 85 3560 LBL

M5 M2 B B T9 B
86
1
FRC1 FRC1

1800 RNG/WHT 1800 RNG/WHT

SHT2/F7
SHT3/C1 C C
ALTERNATOR
2005 BLK 1015 RED
SHT4/B8
GATEWAY CTRLR
1
T43
STARTER RELAY SIGNAL 7 1
3560 LBL FOOT THROTTLE T11
STARTER RELAY FEEDBACK 22 ADAPTER
2150 BRN GND FOOT THROTTLE 1
SHT4/G3 B HARNESS
AIR FILTER 7217683 T12
3150 LBL SWITCH (NC) C115 D 2015 BLK
AIR FILTER SENDER SIGNAL 16 A SIG
E SHT4/E3
FOOT THROTTLE INTDM F
C405 5695 YEL
5695 YEL +5V PWR
SHT12/C8 C C C
3695 LBL 3695 LBL SIG
THROTTLE SECONDARY SIGNAL 33 A A A
2695 BRN 2695 BRN GND
SHT4/G3 B B B

3105 LBL
RIGHT TAILGATE FAN RELAY FEEDBACK 25 C115
3100 LBL
LEFT TAILGATE FANS RELAY FEEDBACK 12

TAILGATE FANS RELAY-C C104 LEFT TAILGATE FAN

TAILGATE FANS CONN FUSE 15 A
8110 TAN 8110 TAN 8125 TAN
C4 1 1 A B A
87
SHT2/C1
1105 RED/WHT
C1 C3
C171 C171 M
30 87a 2400 BLK 2400 BLK
8100 TAN SHT4/D6 2 2 B
C5 C2
86 85 C119
RIGHT TAILGATE FAN
FRC1
FRC1 FUSE 15 A
8105 TAN 8105 TAN 8135 TAN
TAILGATE FAN RELAY OUTPUT 9 3 3 A B A

J1A SHT4/B6
2295 BLK C172 C172 M
2405 BLK 2405 BLK
SHT4/C6 4 4 B
C355
FUEL HARN C113

3180 LBL 3180 LBL HAND THROTTLE

FUEL SENDER SIGNAL 12 C C A
FUEL SENDER F
(30 - 270 OHM) SHT12/C7 E
2180 BRN 2180 BRN D
SHT4/G3 D D B C428
5690 YEL +5V PWR
MFR HARN CONN 2 (LT GRAY) C
C406 3690 LBL
3690 LBL SIG
THROTTLE PRIMARY SIGNAL 10 6 6 A
2430 BRN 2690 BRN GND
SHT4/G3 2 SHT12/D5 B
C120
T
ENGINE TEMP C114
3110 LBL
ENGINE TEMP SIGNAL 18 1 SENSOR (950-4400 OHM)
8007 TAN C120
IGN SW ON 4
INTAKE HEATER
J1B 8020 TAN INTAKE HEATER FUSE CONTACTOR
SHT9/F8 SP74
ENG ECU CTRLR +12V PWR 150 AMPS
1 1060 RED 1 1 1065 RED 1
8008 TAN 87 1 8515 TAN
SP77 8500 TAN 1
IGN SW ON 19 C100 T29 T26 T27 T28 30
2865 BRN GND C100 T30 T14
WATER IN FUEL RETURN 34 2 1445 RED/WHT 1 85 1
WATER IN FUEL SENSOR SHT2/D1 8505 TAN 1
T41 86 T40
(FUEL FILTER)
3865 LBL SIG
T31
WIF SENSOR 9 1
8510 TAN
PRE HEATER RELAY DRIVER 56
C118 KL87 SHT8/B6
1511 RNG/WHT
SHT3/G1 1 1 SHT8/C6
8013 TAN
MAFS FREQU SIGNAL 28 2 2 SHT8/G3
8014 TAN
AIR INLET TEMP 35 3 3 SHT8/F3
1 3420 LBL
4 4 SHT8/H7
T42
J7A ENG-CROSSOVER

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 7 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427 MPS
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 7 / 17
7300861
Printable Version Click Here
549 of 1052
 ENGINE CONTROL UNIT

J7B
ENG ECU CTRLR

GLOW PLUG FEEDBACK

SHT7/B5 79 GLOW PLUG FEEDBACK
EXHAUST GAS TEMP SENSOR (BEFORE TURBO)
EXHAUST GAS TEMP SENSOR 2 RETURN 23 1
EGR VALVE DC MOTOR

T
EXHAUST GAS TEMP SENSOR 2 6 2
1 64 VREF 3 EGR C131
5 16 EGR POSITION SENSOR SIGNAL
3 72 EGR SENSOR RETURN GND
OPEN
MAF SENSOR
4 MAF FREQ
SHT7/B5 1
6 92 EGR H BRIDGE POSITIVE
MASS AIR FLOW SENSOR 5V 37 2
2 93 EGR H BRIDGE NEGATIVE MASS AIR FLOW SENSOR GND 20 3
MAF TEMP
C151 SHT7/B5 4
C136
COOLANT TEMP SENSOR
COOLANT TEMP SENSOR RETURN
OIL PRESSURE & TEMPERATURE SENSOR
1 45
OIL TEMP SENSOR 4 2

T
2 9 COOLANT TEMP SENSOR
VREF 3 OIL PRESSURE 65 3
C149 T
OIL PRESSURE SENSOR 11 4 P
FUEL TEMP SENSOR OIL PRESSURE & TEMP RETURN GND 48 1
1 10 FUEL TEMP SENSOR
C137
T

2 46 FUEL TEMP SENSOR RETURN GND

C148 INTAKE MANIFOLD TEMPERATURE

AIR INTAKE TEMP SENSOR RETURN 69 1
KNOCK SENSOR 1 SHIELD-01

T
SHIELD-01 AIR INTAKE TEMP SENSOR 94 2
1 30 ENGINE BLOCK ACCELEROMETER #1 RETURN
C150
2 31 ENGINE BLOCK ACCELEROMETER #1

ENGINE BLOCK ACCELEROMETER #1 SHIELD

INTAKE MANIFOLD PRESSURE SENSOR
3 28
VREF 2, INTAKE PRESSURE SENSOR 61 1
C147
INTAKE MANIFOLD PRESSURE SENSOR 12 3
KNOCK SENSOR 2 P
SHIELD-02 SHIELD-02
1 33 ENGINE BLOCK ACCELEROMETER #2 RETURN INTAKE MANIFOLD PRESSURE RETURN GND 67 2
2 32 ENGINE BLOCK ACCELEROMETER #2 C138
3 29 ENGINE BLOCK ACCELEROMETER #2 SHIELD
INJECTOR #1
C146 FUEL INJECTOR #1 HSDA 27 1

CRANKSHAFT POSITION SENSOR SHIELD-03

SHIELD-03
1 36 CRANKSHAFT SENSOR NEG FUEL INJECTOR #1 LSD1A 26 2
2 60 CRANKSHAFT POSITION SENSOR C139
3 87 CRANKSHAFT SENSOR SHIELD
INJECTOR #2
C145 FUEL INJECTOR #2 HSDB 50 1

CAMSHAFT SENSOR
VREF 1 CAMSHAFT SENSOR
1 SHT7/B5 FUEL INJECTOR #2 LSD2B 74 2
2 59 CAM SHAFT POSITION SENSOR C140
3 47 CAM SHAFT POSITION SENSOR RETURN
INJECTOR #3
C144 FUEL INJECTOR #3 HSDB 51 1

RAIL PRESSURE SENSOR

3 38 VREF 1 RAIL PRESSURE SENSOR FUEL INJECTOR #3 LSD1B 75 2
1 35 RAIL PRESSURE SENSOR C141
P
RAIL PRESSURE SENSOR RETURN
INJECTOR #4
2 19
FUEL INJECTOR #4 HSDA 3 1
C143

FUEL INJECTOR #4 LSD2A 25 2

INLET METERING VALVE
VREF 1 INLET METERING VALVE
1 SHT7/B5 C142

2 77 INLET METERING VALVE (PWM)

C154
J7B
J7B

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 8 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 8 / 17
7300861
Printable Version Click Here
550 of 1052
 HOSE HEATER MAIN

SHT2/C1
1100 RED/WHT
30
DOSING CONTROL
8090 TAN

86
87

85
2310 BRN
UNIT
RL010 RL010
8310 TAN

2975 BLK 1 T33

DCU CASE GND
2915 BLK

DOSING CONTROL UNIT

SP62
1230 RED/WHT 1245 RED/WHT HOSE RELAY MAIN SIGNAL
SHT2/C1 5 93
1265 RED/WHT
6
1255 RED/WHT
73
CAN JUMPER 67
1275 RED/WHT
51
7998 WHT
CAN JUMPER 68
2880 BLK SP63 2925 BLK
SHT4/G8 1
CAN JUMPER 89 C123
2825 BLK 2935 BLK
SHT6/D4 2 HOSE 1 HEATER
7999 WHT 8320 TAN
2870 BLK CAN JUMPER 90 2
SHT6/F4 2945 BLK
7
8120 TAN
2855 BLK SP87 1
29 HOSE 1 HEATER
8020 TAN 8340 TAN
C123
HOSE 1 RELAY FB SP88
SHT7/C7 22 IGNITION SIGNAL
72
2170 BRN 8330 TAN
1 75 TANK HEATER VALVE GND 30 2955 BLK
87 SP86
TANK HEATING
VALVE 8540 TAN HOSE 1 HEATER 8550 TAN

2985 BLK
4 92 94 86 85

2965 BLK
TANK HEATING VALVE SIG
C155 RL011 RL011
Shield Shield C124
8850 WHT RELAY GROUND 2135 BRN 2145 BRN
1 80 RED AGEN VALVE HIGH
53 HOSE 2 HEATER
SP85 8240 TAN
REDUCTION AGENT 2
METERING VALVE 8950 BLK 2140 BRN
2 58 RED AGENT VALVE LOW
SP92 8140 TAN
C156 2165 BLK 8260 TAN 1
59 HOSE 2 RELAY FB
49 HOSE 2 HEATER
RED AGENT SHIELD SP89 C124
2025 BRN
CATALYST 2 61 CAT TEMP SCR INLET 8250 TAN
C125
TEMPERATURE SCR 30 HOSE 3 HEATER
T 87 8350 TAN
INLET 2
8900 TAN
1 83 CAT TEMP SCR INLET 8560 TAN
HOSE 2 HEATER 50 86 85
C157 8150 TAN
2125 BRN RL012 RL012 1
2050 BRN
2 9 ENV TEMP GND C125
ENVIRONMENTAL
TEMPERATURE T
8800 TAN
1 31 ENV TEMP SIG HOSE 3 HEATER
C159 8370 TAN 8360 TAN
HOSE 3 RELAY FB 27 30
2075 BRN SP61 87
CATALYST 2 12 CAT TEMP DOC INLET
TEMPERATURE DOC 8600 TAN C122
T HOSE 3 HEATER 28 86 85 SUPPLY MODULE
INLET 8530 TAN
1 34 CAT TEMP DOC INLET RL013 RL013
C160 1690 RNG/WHT HEATER BATT+
SM HEATER BATT 4 11
8650 TAN HEATER SIGNAL
SM HEATER SIGNAL 3 12
1695 RNG/WHT PUMP MOTOR BATT +
+5V POWER 55 3
SM PUMP MOTOR 8700 TAN PUMP MOTOR CONTROL SIGNAL
76 2
CONTROL SIGNAL
2095 BRN PUMP MOTOR GND
SM PUMP MOTOR GND 54 4
1680 RNG/WHT PURGING PUMP BATT +
SM PURGING PUMP BATT+ 77 5
8750 TAN PURGING PUMP SIGNAL
SM PURGING PUMP SIGNAL 78 6
1685 RNG/WHT PRESSURE SENSOR BATT+
SM PRESSURE SENSOR BATT+ 17 10
3000 LBL PRESSURE SENSOR SIGNAL
SM PRESSURE SENSOR SIGNAL 39 9
2085 BRN PRESSURE SENSOR GND
SM PRESSURE SENSOR GND 40 8
C121 C121 C122

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 9 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 9 / 17
7300861
Printable Version Click Here
551 of 1052
 HYDRAULICS

2220 BRN GND

GATEWAY CTRLR SHT4/H3 B C425
HYDRAULIC TEMPERATURE SENDER
T B B
500 - 3000 OHM (8 VOLT)
3220 LBL SIG 4200 LGN C308
HYD TEMP SIGNAL 32 A A A A
BRAKE
C108
SOLENOID 9.8
2200 BLK 2200 BLK
SHT4/D6 C C B OHM 12 V TRACK 2 SPEED ADAPTER
3320 LBL SIG (SEE ADDITIONAL OPTIONS DWG)
HYD FILTER DIFF PRESS 34 A C308
HYDRAULIC OIL FILTER SWITCH
2320 BRN GND (NC)
SHT4/H3 B WHEEL 2 SPD ADP HARNESS 7159366
TRACK 2 SPD HARNESS 7243409
C112
TRACK SINGLE SPD BRAKE ADP HARNESS 7234968
4010 LGN SIG
1
HYDRAULIC FAN SOLENOID
2910 BRN GND 7.2 OHM 12 V
HYDRAULIC FAN GROUND 18 2
C446

2410 BRN GND

HYD LOCK VALVE SOL GROUND 1 2
HYDRAULIC LOCK SOLENOID
4410 LGN SIG 9.8 OHM 12 V
1
J1A
C420

2190 BRN GND

SHT4/G3 B
P HYDRAULIC CHARGE
3190 LBL SIG
C PRESSURE 0.5-7.5V
5190 YEL +8 PWR
A
C105
4200 LGN
J1B
19

13

23

6
HYD LOCK
SOLENOID SIGNAL

TRACTION
SOLENOID OUTPUT
HYDRAULIC FAN
SIGNAL

HYD CHARGE PRESS

SENDER SIGNAL

HYD CHARGE PRESS

SENDER POWER

4330 LGN GND

AUX CTRLR 1
FRONT ROD SOLENOID (MALE)
FRONT ROD 2330 BRN SIG 3.3 OHM PWM
18 2
SOLENOID GROUND
C418
4340 LGN GND
1

GATEWAY CTRLR FRONT BASE SOLENOID (FEMALE)

FRONT BASE 2340 BRN SIG 3.3 OHM PWM
1 2
SOLENOID GROUND
J2A C419

J2B
19

13
FRONT ROD
SOLENOID SIGNAL

FRONT BASE
SOLENOID SIGNAL

AUX CTRLR

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 10 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 10 / 17
7300861
Printable Version Click Here
552 of 1052
 1940 RNG/WHT 1
LEFT PANEL BUZZER CAB DISPLAY
SHT3/E1
T13
7040 WHT 1
C499
T2 PTOL CONN

C479 1930 RNG/WHT SWITCHED POWER

LEFT PANEL (BLACK) SHT3/E1 1

2940 BLK GROUND

SHT4/F8 3
BUZZER GATEWAY CTRLR C408
10
MFR HARN CONN 1 (BLACK)
2920 BLK GROUND 3030 LBL 3030 LBL PTOL OUTPUT
SHT4/G8 2 PTOL SWITCH 20 1 1 2

1440 RED/WHT UNSWITCHED POWER 2380 BRN 2380 BRN PTOL LED
SHT2/G1 1 PTOL LED 19 12 12 4

1620 RNG/WHT SWITCHED POWER

SHT3/E1 5 C499
C500
SHT16/F4
3400 LBL
11 LEFT BLINKER INPUT RH KEY SWITCH CONNECTOR

3500 LBL RIGHT BLINKER INPUT 8130 TAN 8130 TAN START
SHT16/F4 8 START ENGINE 24 2 2 2

1960 RNG/WHT J1A

SHT3/E1

SW9
3040 LBL 3040 LBL RUN/ENTER SWITCH
TRAVEL CONTROL SWITCH(OPTIONAL) RUN/ENTER 22 14 14 4

2700 BLK 3650 LBL TRAVEL CONTROL INPUT J1B

SHT4/E8 2 3 7 1950 RNG/WHT SWITCHED POWER
SHT3/D1 5
6
1
1420 RED/WHT UNSWITCHED POWER
5 4 SHT2/G1 1
3600 LBL PARK BRAKE INPUT
SW9 SW9 9
SW1 2960 BLK GROUND
SHT4/F8 3
BRAKE SWITCH
C500
2930 BLK
C503
SHT4/E8 2 1 RH DLX PANEL
C479 SHT5/G1

5 6 1590 RNG/WHT SWITCHED POWER

SHT3/D1 5
4
3 1240 RED/WHT UNSWITCHED POWER
SW1 SHT2/H1 1
SW1
C480 2250 BLK GROUND
1775 RNG/WHT SHT4/F8 3
SHT3/E1 LEFT PANEL CONN (GRAY)

3620 LBL DOOR SIGNAL

SHT12/D3 12
C503 SHT5/F1

3610 LBL PARK BRAKE OUTPUT

2

SW12
DESOX INHIBIT SWITCH(OPT KIT)

2065 BLK 8070 TAN DESOX INHIBIT

SHT4/E8 2 4 9
1700 RNG/WHT 8050 TAN
SHT3/E1 7 9 4
1705 RNG/WHT 8055 TAN DESOX INHIBIT LAMP
SHT3/E1 10 8 5
8060 TAN
3 1
SW12 1
C480
SW12

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 11 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 11 / 17
7300861
Printable Version Click Here
553 of 1052
 CAB
* DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)

C438
*
MFR HARN CONN 3 (DK GRAY) 2795 BLK GND
1850 RNG/WHT 1
SHT3/F1 2 2 C212
1375 RED/WHT +12V PWR POWER SOCKET
2
C212
C408
MFR HARN CONN 1 (BLACK) DOME LIGHT

SHT2/B1
1370 RED/WHT
7 7
1370 RED/WHT SP45 1390 RED/WHT * 1
C129 T37
CAB ACCESSORY
1210 RED/WHT 2010 BLK
A A +12V BATT PWR 1
1580 RNG/WHT 1580 RNG/WHT
SP8 1865 RNG/WHT SP41
SHT3/D1 5 5 B B +12V SW PWR
* T38

2800 BLK
C C GND

1510 RNG/WHT
SHT16/C2

1885 RNG/WHT
SHT16/B3

2730 BLK 2730 BLK SP44 2210 BLK

SHT4/E3 11 11 SHT16/C2

2885 BLK
SHT16/B3

2060 BLK
SHT13/H8
C428
MFR HARN CONN 2 (LT GRAY) C667
SHT4/E3
2790 BLK
14 14
2790 BLK * DOOR HARNESS
(SEE ADDITIONAL
2690 BRN
SHT7/C4 OPTIONS DWG)
2370 BRN 2370 BRN 2375 BRN 1850 RNG/WHT
SHT4/H3 4 4 SEATBAR 1 1 WIPER SWITCH, MOTOR SWITCHED POWER
SP56 SENSOR 3620 LBL
SHT11/D8 4 4 DOOR SIGNAL

2845 BLK
1400 RED/WHT
GATEWAY CTRLR GND
SHT2/H1 5 5 DOOR UNSW PWR
A
3370 LBL 3370 LBL SIG
6 6
SEATBAR SENSOR SIGNAL 11 5 5 B 2840 BLK
+5V PWR
2 2 WIPER MOTOR GROUND
C
SP13 SP52
5100 YEL 5370 YEL 5370 YEL 5375 YEL 7310 WHT
5V CTRLR POWER 24 3 3 3 3 WASHER SIGNAL
C482

J1B 5690 YEL

5695 YEL SHT7/D4
SHT7/F7
HARNESS WASHER PUMP
* C252
7253378
2845 BLK GND
B B 2
WASHER
MOTOR
7310 WHT PWR
A A 1
C253

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 12 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 12 / 17
7300861
Printable Version Click Here
554 of 1052
 *
SW4
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
SWITCH

SHT3/E1
1785 RNG/WHT
2 1
6
CONTROLS
SHT12/D1
2060 BLK
5
* DLX CAB HARN 7301237 ONLY
4 (NOT IN STD CAB HARN 7303755)
SW4 3
SW4
DRIVE CTRLR C438
MFR HARN CONN 3 (DK GRAY)
4235 LGN 4235 LGN
HAND CONTROL LIGHT 8 7 7

4275 LGN 4275 LGN

FOOT CONTROL 6 8 8

4550 LGN 4550 LGN

FOOT CONTROL SIGNAL 21 9 9 C536
RIGHT SWASHPLATE CONN RIGHT SWASHPLATE
2810 BRN 2810 BRN
4 4 A
C103
DRIVE CTRLR 1710 RNG/WHT 1710 RNG/WHT
TAILGATE HARN SHT3/B1 1 1 B
7100 WHT 7100 WHT T19 3810 LBL 3810 LBL
BACKUP ALARM POWER 17 C C RIGHT SWASHPLATE ANGLE 10 3 3 C
1 BACK UP ALARM 5890 YEL SP84 5810 YEL
J5A 2650 BLK 1 SENSOR SUPPLY +5V 23 2 2 C543
SHT4/D8
T20 2890 BRN
MAIN SENSOR GND 17 SP83
C537
LEFT SWASHPLATE CONN LEFT SWASHPLATE
2860 BRN 2860 BRN
4 4 A
1770 RNG/WHT 1770 RNG/WHT
SHT3/B1 1 1 B
3860 LBL 3860 LBL
LEFT SWASHPLATE ANGLE 18 3 3 C
5860 YEL
2 2 C542

C501
A22 PUMP CONN RIGHT FORWARD DRIVE
ACS CTRLR 4260 LGN 4260 LGN
RIGHT FWD DRIVE 26 1 1 1
LIFT ACUTATOR
MOTOR POWER F
LIFT ACTUATOR 2660 BRN 2660 BRN
4600 LGN RIGHT REV DRIVE 25 2 2 2
LIFT ACTUATOR 5
MOTOR GROUND D C546
J3C LEFT REV DRIVE 19 RIGHT REVERSE DRIVE
4610 LGN
8 4250 LGN 4250 LGN
2980 BRN 3 3 1
1
5980 YEL LEFT FWD DRIVE 7
3 2650 BRN 2650 BRN
3980 LBL
J5B 4 4 2
LIFT ACTUATOR
FEEDBACK
H 2
C547
C429
LEFT REVERSE DRIVE
TILT ACTUATOR 4280 LGN
4280 LGN
TILT ACTUATOR 3990 LBL 5 5 1
FEEDBACK
E 2
5990 YEL RIGHT FWD GND 26
J3B 3 2680 BRN 2680 BRN
2970 BRN SP5 2990 BRN
6 6 2
ACS GND G 1 RIGHT REV GND 27
4640 LGN
C545
5970 YEL 5
+5V SUPPLY A LEFT REV GND 18 LEFT FORWARD DRIVE
SP29 4270 LGN 4270 LGN
J3A 4650 LGN 7 7 1
8
TILT ACTUATOR FWD A
C427 2670 BRN 2670 BRN
LEFT FWD GND 10 8 8 2
TILT ACTUATOR REV K
C544
J3C A22 PUMP HARNESS

C474
BRAKE CONN
4210 LGN
BRAKE LIGHT SIG 9 A A
J5A

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 13 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 13 / 17
7300861
Printable Version Click Here
555 of 1052
 6100 PNK
C434-1
A
LIGHTS
SIG

37 WATT

C408
2735 BLK GND
MFR HARN CONN 1 (BLACK) B LEFT FRONT
2765 BLK 2765 BLK SP14 2750 BLK WORKLIGHT
SHT4/F3 9 9 B
GND

50 WATT

6110 PNK SIG

A
C434-2

C435-1
6000 PNK 6000 PNK 6120 PNK
8 8 SIG
A
SP15
FRONT WORK LIGHTS 37 WATT
RELAY - RC1
C438
2760 BLK GND
1350 RED/WHT MFR HARN CONN 3 (DK GRAY) B RIGHT FRONT
SHT2/E1 30 6620 PNK SP23 6610 PNK 6610 PNK 6130 PNK WORK LIGHT
87 13 13 A
SIG
SP64
86 85 50 WATT

2705 BLK GND

RC1 RC1 B
C435-2
2120 BLK
SHT4/B8

6630 PNK
6320 PNK

FRONT WORK LIGHTS 2610 BLK GND

SHT4/D8 2
RELAY - RC2
C103 RIGHT REAR
1330 RED/WHT
30 TAIL LIGHT
SHT2/E1 TAILGATE HARN
87 6340 PNK SP10 6310 PNK 6310 PNK
SP49 6320 PNK SIG
A A 1
86 85 C603

RC2 RC2
2115 BLK 6330 PNK SIG
SHT4/B8 1
LEFT REAR
GATEWAY CTRLR TAIL LIGHT
2640 BLK GND
MRKR LIGHT PWR
SHT4/D8 2
5
RELAY SIGNAL C602
MRKR LIGHT PWR 3460 LBL
31
RELAY FEEDBACK

REAR LIGHT RELAY SIGNAL 17 T16 TERMINAL (-)

2620 BLK
3440 LBL SHT4/D8
GND 1
REAR LIGHT RELAY FEEDBACK 28
RIGHT REAR
6210 PNK

FRC1 WORK LIGHT

J1A
REAR LIGHT 6210 PNK SIG 1
RELAY - E T15 TERMINAL (+)

1320 RED/WHT T17 TERMINAL (+)

SHT2/E1 E1 87 6200 PNK 6200 PNK 6220 PNK
30 E4 H H SIG 1
SP96
85 LEFT REAR
E5 E2 WORK LIGHT
86
2630 BLK GND 1
SHT4/C8
FRC1 FRC1 T18 TERMINAL (-)
2045 BLK
SHT4/B8

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 14 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 14 / 17
7300861
Printable Version Click Here
556 of 1052
 2440 BLK GND
* HVAC
2
* DLX CAB HARN 7301237 ONLY
HVAC DUCT FAN (NOT IN STD CAB HARN 7303755)
M
7440 WHT SIG
1
C610

2560 BLK
*
C
7420 WHT POTENTIOMETER (TEMP
A
CONTROL SWITCH)
7425 WHT
B
C483

*
D
2130 BLK HEATER VALVE
C
7430 WHT
A
SP48
C635

2030 BLK
SHT4/B8

BLOWER MOTOR
FRC1
HVAC RELAY-B
C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
(DK GRAY) 1
1140 RED/WHT 1500 RNG/WHT 1500 RNG/WHT 2 7520 WHT MED
SHT2/E1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT LOW
SW10 3
85
B5 B2 3
86
7050 WHT

FRC1 FRC1 SW10 M

7410 WHT
4
GATEWAY CTRLR
C611

HVAC RELAY SIGNAL 3

7400 WHT
3050 LBL
HVAC RELAY FEEDBACK 30

2745 BLK 2745 BLK 2580 BLK

SHT4/F3 11 11
SP16 2100 BLK

SW11
1
3

C
SP40 * THERMOSTAT

AC SIGNAL MONITOR 11
7021 WHT 7020 WHT
12 12
7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH

7023 WHT
B
AC EVAPORATOR
SWITCH 7024 WHT 7025 WHT SIG
A 1
D4

C350 MAGNET CLUTCH

2290 BLK 2280 BLK (COMPRESSOR)
SHT4/C6
GND
2
C486

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 15 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 15 / 17
7300861
Printable Version Click Here
557 of 1052
 C355 C428
# FUEL HARN MFR HARN CONN 2 (LT GRAY)

POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
11 11
4470 LGN
OPTIONS 1
CLOSE
2470 BLK 2770 BLK 2770 BLK
2 GND SW5
C607
SP33
B B SHT4/E6
* POWER BOBTACH SWITCH # DLX FUEL HARN 7266824 ONLY
# 4480 LGN 4480 LGN 4480 LGN 1380 RED/WHT 1
(NOT IN STD FUEL HARN 7149219)
1 SIG F F 10 10 2
3 DLX CAB HARN 7301237 ONLY
POWER BOB
OPEN 2480 BLK SW5
* (NOT IN STD CAB HARN 7303755)
GND
2 SW5
C606
LEFT HANDLE 6010 PNK 6010 PNK
13 13
LIFT (ACS/AHC ONLY) LEFT HANDLE (FLASHER) 5 WAY
(SEE ADDITIONAL OPTIONS DWG) 1550 RNG/WHT 1550 RNG/WHT
SHT3/F1 12 12

C438 1405 RED/WHT

SHT17/D6
MFR HARN CONN 3 (DK GRAY)
HANDLE LOCK (ACS ONLY) 1410 RED/WHT 1410 RED/WHT SP43 1430 RED/WHT
SHT2/B1 1 1 X T3
* FLASHER
1200 RED/WHT L
FLOAT (ACS/AHC ONLY)

3500 LBL
T3
SHT11/F8 D14
SP21 6500 PNK 6500 PNK 6530 PNK
RIGHT POSTION SWITCH
6 6

PADDLE
SP22 6400 PNK 6400 PNK
D13
6430 PNK
* SW2
3 3 BEACON SWITCH
3400 LBL

6510 PNK
6410 PNK
B SHT11/G8 1
6415 PNK SW3 2
C103
LEFT POSITION SWITCH
D
6515 PNK TAILGATE HARN * HAZARD SWITCH
A
E E 1
C411 EURO TAIL LIGHTS 2 6
TRIGGER
(SEE ADDITIONAL
OPTIONS DWG) D D 3 SW2 SW2

2780 BLK 2780 BLK 4

SHT4/E3 4 4 5 6 2850 BLK SP46 2725 BLK

* SW6
BUCKET POSITION SWITCH
SW3
(PINS 3 & 6
SW3

4450 LGN 4455 LGN 4455 LGN INTERNALLY INSULATED) 6570 PNK
BUCKET A SIG 5 5 1
POSITION 2
D3

SOLENOID 3
9.8 OHM B GND
2450 BLK 2455 BLK
SHT4/C6 4 SHT17/F6
2905 BLK

2970 BLK 6700 PNK

*
C423 6 5 SHT17/F4 E E
2810 BLK 2420 BLK C670
SW6 SW6 SHT17/D4 D D
6440 PNK BEACON/FLASHER
LEFT HANDLE F F
2830 BLK
SHT4/E8
EXTERIOR HARNESS
LIFT (ACS/AHC ONLY) 6540 PNK
B B (SEE ADDITIONAL
LEFT HANDLE (HORN) 2 WAY AUX CTRLR OPTIONS DWG)
(SEE ADDITIONAL OPTIONS DWG) C497 C676 C C
HORN SIGNAL 5
7200 WHT
C C
SJC HORN/BLINKER
LEFT SPEAKER
* * RADIO CONN A A

6420 PNK (SEE ADDITIONAL 7820 WHT LEFT

HANDLE LOCK (ACS ONLY) RIGHT BLINKER SIGNAL 4 A A 1 3 SPEAKER (+)

6520 PNK
OPTIONS DWG)
7830 WHT
LEFT
*
LEFT BLINKER SIGNAL 3 B B 2 4 1
SPEAKER (-)
FLOAT (ACS/AHC ONLY) HIGH FLOW
C279 2
2460 BRN
SOLENOID GROUND 26 RIGHT SPEAKER L010
3
J2A GND
B
* 7810 WHT RIGHT SHT12/E1
1510 RNG/WHT
4
AIR RIDE SEAT
RIGHT POSTION SWITCH HIGH FLOW PWR
2 6 SPEAKER (-) PWR
SOLENOID
SIG 7.5 OHM 12 V 7800 WHT RIGHT
PADDLE A 1 5 SPEAKER (+) 2210 BLK GND
SHT12/E1 5
C415 C278 1885 RNG/WHT GND
HIGH FLOW 4460 LGN
26 SHT12/E1 1 6
SOLENOID SIGNAL
J2B 2885 BLK
C277
LEFT POSITION SWITCH
SHT12/D1 2
C408 GATEWAY CTRLR
C676
MFR HARN CONN 1 C126
1460 RED/WHT
A SHT2/B1 (BLACK) HORN CONNECTOR TWO SPEED GROUND 26 2350 BRN
TRIGGER GND
7210 WHT 7210 WHT SIG 2
B 13 13 A A J1A TWO SPEED TRACK 2 SPEED
_
C412 SOLENOID (SEE ADDITIONAL
HORN 4350 LGN OPTIONS DWG)
SIG
1 5.1 OHM 12 V
2785 BLK GND +
SHT4/E8 B B TWO SPEED SIGNAL 26 C441

J1B

Wiring Schematic T870 S/N ASWT11947

S850 AJ9C11246 &&Above
Above WARNING PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 16 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 16 / 17
7300861
Printable Version Click Here
558 of 1052
 *SW7
AUX CTRLR
3410 LBL
C438
MFR HARN CONN 3 (DK GRAY)
14 14
3410 LBL
RIDE CONTROL

1 2
2890 BLK
OPTIONS 2
RIDE CONTROL SW AUTO 23 SHT4/E8
* DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)
SW7 SW7

3480 LBL
RIDE CONTROL RELAY SIG 7 RIDE CONTROL
RELAY - L
FUSE RELAY CENTER

1575 RNG/WHT
3415 LBL SP9 3425 LBL L1 SHT3/F1
RIDE CONTROL RELAY FEEDBACK 21 L4
3435 LBL 3445 LBL 2505 BLK
1 1 L5 L2 SHT4/C8

RIDE CONTROL FRC1

RIDE CONTROL FRC1
COIL SP32 2020 COIL
2040 BLK BLK
2 2
C439 C440
2155 BLK
SHT4/G8

C428
*SW13
MFR HARN CONN 2 (LT GRAY) REVERSING FAN
3475 LBL 3475 LBL
REVERSING FAN MAN SIGAL 16 7 7 3

2905 BLK 2970 BLK

SHT16/D3 1 2 SHT16/D3
3470 LBL 3470 LBL
REVERSING FAN AUTO SIGNAL 29 8 8 6
1565 RNG/WHT
5 SHT3/D1
4
C443
2175 BRN
SW13 SW13
REVERSING FAN RETURN SIG 27 2
J2A REVERSING FAN
COIL
3485 LBL
REVERSING FAN SIG 25 5105 YEL 1

2185 BRN
SHT4/C3 A
3455 LBL RIDE CONTROL
RIDE CONTROL
10 C PRESSURE SENSOR
PRESSURE SENSOR SIG
RIDE CONTROL SENSOR 5V SUPPLY 24 B * SW8 C672
SIDELIGHT SIDELIGHT CONN
J2B C442 6710 PNK/WHT
1405 RED/WHT 1 1 1
SHT16/G3 2
2810 BLK
SHT16/D3 2 2
2860 BLK
6 SHT4/E8

SW8 SW8

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SJC Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7300861 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SJC
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 17 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 17 / 17
7300861
Printable Version Click Here
559 of 1052
 CONNECTOR ASSIGNMENTS
NUM NUM NUM NUM
CONN DESCRIPTION OF SHEET CONN DESCRIPTION OF SHEET CONN DESCRIPTION OF SHEET CONN DESCRIPTION OF SHEET
PINS PINS PINS PINS
C100 WATER IN FUEL SENDER 2 9 C277 AIR RIDE SEAT 6 17 C480 LEFT PANEL(GRAY) 12 12 J5 DRIVE CONTROLLER 48 4,5,6,7,14
C103 TAILGATE HARNESS 8 6,14,15,17 C278 RIGHT SPEAKER 2 17 C482 SEATBAR SENSOR 3 13 J7A ENG ECU CONTROLLER (BCT) 58 5,6,8,9
C104 TAILGATE FANS 4 9 C279 LEFT SPEAKER 2 17 C483 TEMP CONTROL SWITCH 3 16 SW1 BRAKE SWITCH 6 12
C105 HYD CHARGE PRESSURE 3 11 C308 BRAKE SOLENOID 2 11 C486 AC COMPRESSOR 2 16 SW2 BEACON SWITCH 6 17
SENSOR
C108 HYD TEMPERATURE SENDER 2 11 C350 AC EVAPORATOR SWITCH 2 16 C489 MFR ACCESSORY 2 5,6 SW3 HAZARD SWITCH 6 17
C111 MFR-BCT ENG HARN CONN 3 9 C355 FUEL HARNESS 6 9,17 C497 SJC HORN/BLINKER 3 17 SW4 HAND/FOOT, H/ISO SWITCH 6 14
C112 HYD OIL FILTER SWITCH 2 11 C405 AIR FILTER SWITCH 2 9 C499 PTOL 4 12 SW5 POWER BOBTACH SWITCH 6 17
C113 RIGHT TAILGATE FAN CONN 2 9 C406 FUEL SENDER 2 9 C500 RH KEY SWITCH 6 12 SW6 BUCKET POSITION SWITCH 6 17
C114 HAND THROTTLE 6 9 C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,12,13, C501 A22 PUMP HARN CONN 8 14 SW9 TRAVEL CONTROL SWITCH 6 12
15,17
C118 ENG-CROSSOVER 4 9 C411 LEFT HANDLE 5 WAY 5 17 C503 RH DLX PANEL 6 7,12 SW10 BLOWER SWITCH 5 16
C119 LEFT TAILGATE FAN CONN 2 9 C412 LEFT HANDLE 2 WAY 2 17 C536 A22 PUMP HARN - R SWASH 4 14 SW11 AC SWITCH 3 16
C120 ENGINE TEMP SENSOR 2 9 C415 HIGH FLOW SOLENOID 2 17 C537 A22 PUMP HARN - L SWASH 4 14 SW12 DPF SWITCH 10 12
C121 DOSING CONTROL UNIT 94 8,10 C418 FRONT ROD 2 11 C542 LEFT SWASH PLATE 3 14 T1 BATT GROUND 1 6
C122 SUPPLY MODULE 12 10 C419 FRONT BASE 2 11 C543 RIGHT SWASH PLATE 3 14 T2 BUZZER GROUND 1 12
C123 HOSE 1 HEATER 2 10 C420 HYD LOCK 2 11 C544 LEFT FORWARD DRIVE 2 14 T3 FLASHER 2 17
C124 HOSE 2 HEATER 2 10 C421 TILT SPOOL LOCK 3 14 C545 LEFT REVERSE DRIVE 2 14 T4 MEGAFUSE 1 4
C125 HOSE 3 HEATER 2 10 C422 LIFT SPOOL LOCK 3 14 C546 RIGHT FORWARD DRIVE 2 14 T6 BATT GROUND 1 6
C126 HORN 2 17 C423 BUCKET POSITION 2 17 C547 RIGHT REVERSE DRIVE 2 14 T8 BATT GROUND 1 6
C129 CAB ACCESSORY 3 13 C425 BRAKE SOLENOID 3 11 C602 LEFT REAR TAIL LIGHT 2 15 T10 ENGINE SYSTEM GROUND 1 6
C155 TANK HEATING VALVE 4 10 C426 CAN (Remote Start Tool, ACD) 7 7 C603 RIGHT REAR TAIL LIGHT 2 15 T13 BUZZER POWER 1 12
C156 REDUCTION AGENT METERING 2 10 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,9,13,17 C606 POWER BOBTACH OPEN 2 17 1 9
T14 PRE HEATER
VALVE
C157 CATALYST TEMP SCR INLET 2 10 C434-1 LEFT FRONT LIGHT (37W) 2 15 C607 POWER BOBTACH CLOSE 2 17 T15 RIGHT REAR WORK LIGHT(+) 1 15
C158 CATALYST TEMP SCR OUTLET 2 10 C434-2 LEFT FRONT LIGHT (50W) 2 15 HVAC DUCT FAN 2 T16 RIGHT REAR WORK LIGHT(-) 1 15
C610 16
C159 ENVIRONMENTAL TEMP 2 10 C435-1 RIGHT FRONT LIGHT (37W) 2 15 C611 BLOWER MOTOR 4 16 T17 LEFT REAR WORK LIGHT (+) 1 15
C160 CATALYST TEMP DOC INLET 2 10 C435-2 RIGHT FRONT LIGHT (50W) 2 15 C630 THERMOSTAT 3 16 T18 LEFT REAR WORK LIGHT (-) 1 15
C161 DEF TANK 4 8 C438 CAB-MFR HARN CONN(DK GRY) 14 13,14,15,16, C635 HEATER VALVE 6 16 T19 BACKUP ALARM 1 14
17
C163 NOx PRETREATMENT 5 8 C441 TWO SPEED SOLENOID 2 17 C667 DOOR HARNESS 6 13 T20 BACKUP ALARM (GND) 1 14
C164 NOx POST TREATMENT 5 8 C446 HYDRAULIC FAN SOLENOID 2 11 C670 EXTERIOR BEACON HARNESS 6 17 T26 FUSE 150 AMP 1 9
C169 ENGINE CAN DIAGNOSTIC 6 8 C449 LEFT JOYSTICK(CAB HARN) 4 7,14 C676 RADIO 6 17
T27 PRE HEATER CONTACTOR PWR 1 9
C171 INLINE FAN FUSE LEFT 2 9 C450 RIGHT JOYSTICK(CAB HARN) 4 7,14 FRC1 FUSE RELAY CENTER 112 4,5,9,15,16 T29 BATTERY 1 9

C172 INLINE FAN FUSE RIGHT 2 9 C459 LEFT HANDLE 4 14 J1A GATEWAY CONTROLLER 34 5,9,11,12,
T32 ECU CASE GND 1 6
14,15,16,17
C212 POWER SOCKET 2 13 C460 RIGHT HANDLE 4 14 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,11
T31 PREHEATER 1 9
12,14,13,17
C252 WASHER ADAPTER INTMD 2 13 C474 BRAKE (ROAD KIT) 1 14 J2A AUX CONTROLLER 34 11,17 T33 DCU CASE GND 1 10

C253 WASHER PUMP 2 13 C479 LEFT PANEL(BLACK) 12 7,12 J2B AUX CONTROLLER 26 4,5,6,7,11 1 13
T37 DOME LIGHT +
17
T38 DOME LIGHT - 1 13
T42 PREHEATER FDBK 1 9

WIRING SCHEMATIC
(SCPA MACHINE) Printable Version Click Here
T870 (S/N ASWT11001 - ASWT11601)
(S/N B3BZ11001 - B3BZ11129)
Sheet 1 of 18
Printed In U.S.A.
(PRINTED DECEMBER 2016)
7222673 (B)
560 of 1052
 J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER)
PIN FUNCTION PIN FUNCTION
PIN FUNCTION PIN FUNCTION A-1 FRONT AUX (F) RETURN (BASE) B-1
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS
A-2 B-2 UNSW BATT
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT
A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-3 HVAC RELAY - B B-3 UNSW BATT
A-4 RIGHT BLINKER RELAY B-4
A-4 SWITCHED PWR OUT RELAY - A B-4 ENGINE RUN SIGNAL
A-5 HORN RELAY B-5
A-5 FRONT LIGHT RELAY - J B-5 LIFT SPOOL LOCK
A-6 B-6
A-6 B-6 TRACTION LOCK HOLD
A-7 B-7
A-7 STARTER RELAY - M B-7 TILT SPOOL LOCK
A-8 B-8 CAN LO 1
A-8 B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 TAILGATE FANS OUT RELAY - C B-9 CAN HI 1
A-10 B-10
A-10 TILT SPOOL LOCK RETURN B-10 HAND THROTTLE
A-11 B-11
A-11 AC SENSE B-11 SEAT BAR
A-12 B-12
A-12 LEFT FAN FDBK RELAY - C B-12 FUEL LEVEL
A-13 B-13 FRONT AUX (F) (BASE)
A-13 B-13 BICS HYD LOCK HOLD
A-14 B-14 CAN HI 2
A-14 B-14 CAN HI 2
A-15 B-15 GROUND
A-15 B-15 GROUND P1
A-16 B-16 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2
A-17 B-17 RH PWM LO
A-17 REAR LIGHT RELAY - E B-17 GROUND P3, SENSOR
A-18 FRONT AUX (M) RETURN (ROD) B-18 RH PWM SIG
A-18 HYD FAN RETURN B-18 ENGINE TEMP SENSOR
A-19 B-19 FRONT AUX (M) (ROD)
A-19 PTOL LED B-19 HYD FAN OUTPUT
A-20 B-20 CAN LO 2
A-20 PTOL SWITCH B-20 CAN LO 2
A-21 B-21 RH TRIGGER RETURN
A-21 SWITCHED PWR FDBK RELAY - A B-21 REMOTE RUN KEY
A-22 B-22 SWITCHED PWR
A-22 STATER FDBK RELAY - M B-22 RUN/ENTER
A-23 B-23 RH PWM HI
A-23 B-23 SENSOR SUPPLY 8V
A-24 B-24
A-24 START ENGINE B-24 SENSOR SUPPLY 5V
A-25 B-25
A-25 RIGHT FAN FDBK RELAY - C B-25
A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-26 TWO SPEED RETURN B-26 TWO SPEED COIL
A-27
A-27
A-28
A-28 REAR LIGHT FDBK RELAY - E
A-29
A-29
A-30
A-30 HVAC FDBK RELAY - B
A-31
A-31 FRONT LIGHTS FDBK RELAY - K
A-32
A-32 HYD OIL TEMP (8 VOLT)
A-33
A-33 FOOT THROTTLE
A-34
A-34 HYD OIL FILTER SW1

HARNESS PART NUMBER

EXLF MFR SCPA 7267012
DLX CAB 7253375 Printable Version Click Here
DLX FUEL 7266824
BCT ENG 7242470 WIRING SCHEMATIC
TAILGATE DOM 7267103
SUSP JSTK 7163706 (SCPA MACHINE)
BRAKE ADAPTER 7234968
WHL 2 SPD ADP 7159366 T870 (S/N ASWT11001 - ASWT11601)
TRK 2 SPD ADP 7214627
(S/N B3BZ11001 - B3BZ11129)
Sheet 2 of 18
Printed In U.S.A. (PRINTED DECEMBER 2016)
7222673 (B)
561 of 1052
 LEGEND
ENGINE CONTROLLER WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX PARTIAL CONNECTOR
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1-3
CONNECTOR J7
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 4-5
PIN FUNCTION
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 6
1 SW POWER BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 7-8
2 GND BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 9-10 CONNECTOR
3 CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 11
SW POWER
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 12
4 GND
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB PAGE 13
5 SW POWER CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
CONTROLS PAGE14
6 GND LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 15
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT JOIN ONE WIRE)
9 WATER FUEL SENSOR HVAC PAGE 16
ENGINE 8000 THROUGH 8999 TAN TAN SHEET #
SIGNAL OPTIONS PAGE 17
13 COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
14
15

19 ECU RUN SIGNAL

21

24
25
26
28 MASS AIR FLOW (MAF)
SENSOR FREQUENCY
29
33

34 WATER FUEL SENSOR

GROUND
35 MASS AIR FLOW (MAF)
SENSOR TEMP
45 SW POWER SIGNAL
47 ECU CAN 1 LOW
48 ECU CAN 1 HI
56 PREHEATER SIGNAL Printable Version Click Here

WIRING SCHEMATIC
(SCPA MACHINE)
T870 (S/N ASWT11001 - ASWT11601)
(S/N B3BZ11001 - B3BZ11129)
Sheet 3 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222673 (B)

562 of 1052
 UNSWITCHED BATT POWER C408 1240 RED/WHT SHEET 12
(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
1400 RED/WHT
SP7 SHEET 13
1450 RED/WHT 6 1450 RED/WHT C667 DOOR HARNESS
FRC1 FUSE RELAY CENTER 1420 RED/WHT
SHEET 12
1110 RED/WHT 2 C500 RH KEY SWITCH
FUSE 11 25 A J1B
1070 RED 1120 RED/WHT 1130 RED/WHT 3 GWY CTRLR 1440 RED/WHT
SHEET 12
SP2
C479 LH PANEL
+12V 1025 RED
FUSE 13 25 A
1160 RED/WHT SP36 1150 RED/WHT 3
J2B
BATTERY MEGAFUSE 1180 RED/WHT 2 AUX CTRLR
100.0 Amps

T4
FUSE 17 25 A
1280 RED 1235 RED/WHT SP58 1260 RED/WHT 48
J5
SHEET 9 1250 RED/WHT 47 DRIVE CTRLR
STARTER
FUSE 4 25 A
1010 RED 1140 RED/WHT
SHEET 16
FRC1 HVAC RELAY
1310 RED

FUSE 1 15 A 1320 RED/WHT

SHEET 15
FRC1 REAR LIGHT RELAY
FUSE 2 20 A 1350 RED/WHT SHEET 15
1340 RED FRC1 FRONT LIGHT RELAY
SP26
1330 RED/WHT
SHEET 15
FRC1 FRONT LIGHT RELAY
FUSE 20 5 A
1335 RED 1345 RED/WHT SHEET 5
FRC1 ENGINE ECU RELAY
FUSE 16 25 A
1325 RED SP1 1300 RED 1035 RED/WHT SHEET 5
FRC 1 ENGINE ECU RELAY
1445 RED/WHT
SHEET 9
FRC1 PRE HEATER RELAY
FUSE 18 25 A
1190 RED 1165 RED/WHT SHEET 7 C426 REMOTE RUN, ACD
1095 RED 1100 RED/WHT SHEET 10
HEATER HOSE RELAY
Printable Version Click Here
1220 RED 1230 RED/WHT DCU POWER
SHEET 10

SHEET 9
1460 RED/WHT C412 LH HANDLE HORN
SHEET 17
WIRING SCHEMATIC
1045 RED 10 1105 RED/WHT 10

FUSE 22 25 A
TAILGATE FANS RELAY PWR C408 CAB-MFR CONN
(OPTIONS)
(SCPA MACHINE)
1040 RED 1490 RED/WHT 1410 RED/WHT
SP60 FUSE 24 25 A
SP24
SHEET 17
T870 (S/N ASWT11001 - ASWT11601)
1055 RED 1290 RED 1370 RED/WHT
SHEET 13
C408 CAB-MFR CONN (S/N B3BZ11001 - B3BZ11129)
(ACCESSORIES)
1050 RED
SHEET 5
FRC1 SWITCHED PWR RELAY
Sheet 4 of 18
1030 RED
SHEET 9
FRC1 STARTER RELAY
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222673 (B)
563 of 1052
 FRC1
ENGINE ECU
1525 RNG SHEET 8
SCR INTERCONNECT SWITCHED POWER J7A ENGINE ECU
+12V RELAY - G
PWR 1506 RNG/WHT 1
SHEET 4 1035 RED/WHT 30 SP73 SP54
87 1540 RNG/WHT 1545 RNG/WHT 1507 RNG/WHT 3

1509 RNG/WHT 1508 RNG/WHT 5

85 86
8005 TAN 45

FRC1 FUSE RELAY CENTER

SHEET 4 1345 RED/WHT
FUSE 21 15 A
1511 RNG/WHT
SHEET 9 ENG-CROSSOVER

FUSE 5 25 A C489
1780 RNG/WHT A MFR ACCESSORY
FUSE 6 25 A
1760 RNG/WHT 1850 RNG/WHT
SHEET 13 C408 CAB-MFR CONN (FR WIPER)
1700 RNG/WHT SHEET 12 SW12 DPF SWITCH
1705 RNG/WHT SHEET 12 SW12 DPF SWITCH
FUSE 12 15 A
1790 RNG/WHT 1550 RNG/WHT 1620 RNG/WHT
SHEET 17 C408 CAB-MFR CONN (BKT POSITION) SHEET 12 C479 LH PANEL (BLACK)
1940 RNG/WHT
SHEET 12 T13 LH PANEL BUZZER
1930 RNG/WHT
SHEET 12 C499 RH PANEL PTOL
1775 RNG/WHT
SHEET 12 SW1 BRAKE SWITCH
C428 1960 RNG/WHT
FUSE 14 5 A J2B (LT GRAY) SHEET 12 SW9 TRAVEL CONTROL SWITCH
1805 RNG/WHT 1560 RNG/WHT 22 1785 RNG/WHT
AUX CTRLR CAB-MFR HARN CONN 2 SHEET 14 SW4 H/ISO SWITCH
1950 RNG/WHT
SHEET 12 C500 RH PANEL KEY SWITCH
1660 RNG/WHT 2 1660 RNG/WHT SP42 1590 RNG/WHT
SHEET 12 C503 RH DELUXE PANEL
1765 RNG/WHT SP25 1795 RNG/WHT FUSE 7 25 A
1730 RNG/WHT SP65 1735 RNG/WHT
SHEET 7 C426 REMOTE RUN, ACD
FRC1
1725 RNG/WHT
SWITCHED SHEET 8 C169 ENGINE CAN
POWER RELAY - A FUSE 8 25 A
+12V 1580 RNG/WHT
SHEET 13 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
PWR
1050 RED 30
SHEET 4 FUSE 23 15 A
87 1815 RNG/WHT 1800 RNG/WHT Printable Version Click Here
SHEET 9 ALT EXCITATION
GND 85
SHEET 6
2055 BLK 86
WIRING SCHEMATIC
3450 LBL 21
C428

3380 LBL 4
J1A
GWY CTRLR (LT GRAY)
CAB-MFR HARN CONN 2
(SCPA MACHINE)
1920 RNG/WHT 9 1920 RNG/WHTSP37 1840 RNG/WHT SHEET 7
C449 LH JOYSTICK
T870 (S/N ASWT11001 - ASWT11601)
1830 RNG/WHT
SHEET 7
C450 RH JOYSTICK
(S/N B3BZ11001 - B3BZ11129)
50 J5
1630 RNG/WHT
DRIVE CTRLR Sheet 5 of 18
1740 RNG/WHT SP52
(PRINTED DECEMBER 2016)
1770 RNG/WHT SHEET 14 C537 A22 PUMP HARN (LH SWASH)
1710 RNG/WHT SHEET 14 C536 A22 PUMP HARN (RH SWASH)
7222673 (B)
Printed In U.S.A.

564 of 1052
 SHEET 11 2320 BRN

GROUND
C112 HYD OIL FILTER SWITCH
2370 BRN J1B
SHEET 13 GWY CTRLR
C408 CAB-MFR CONN (SEATBAR SENSOR)
2220 BRN SP12 2230 BRN 17
SHEET 11
C108 HYD TEMP SENDER
2190 BRN
2 2001 BLK SHEET 11
C105 HYD CHG PRESSURE SENDER
4 2002 BLK SP53 2820 BLK SP75 2805 BLK 2180 BRN
J7A SHEET 9
ENG ECU CTRLR 6 2003 BLK C355 FUEL HARN (FUEL SENDER)
2150 BRN
SHEET 9
27 2040 BLK SP50 2235 BLK C405 AIR FILTER SWITCH
T32 2004 BLK J5
ECU CASE GND DRIVE CTRLR 28 2490 BLK 2690 BRN
SHEET 9
2880 BLK C408 CAB-MFR CONN (HAND THRTL)
SHEET 10
C120 SCR-MFR CONN
2430 BRN 18
2080 BLK SHEET 9
SHEET 7 ENGINE TEMP GND
C449 LH JOYSTICK T6
2070 BLK BATT GND
SHEET 7 C408
C450 RH JOYSTICK (BLACK)
2920 BLK CAB-MFR HARN CONN 1
SHEET 12 2765 BLK
C479 LH PANEL (BLACK) SHEET 15
2940 BLK SP4 2950 BLK 10 2950 BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 12
C499 PTOL 2745 BLK
SHEET 16
2960 BLK 16 SP3 C408 CAB-MFR CONN (HVAC)
SHEET 12 2510 BLK 2110 BLK
C500 RH PANEL KEY SWITCH J1B 2790 BLK T8
2250 BLK GWY CTRLR 15 2500 BLK SHEET 13 BATT GND
SHEET 12 C408 CAB-MFR CONN (ACCESSORIES)
C503 RH DELUXE PANEL 2780 BLK
2065 BLK C428 SHEET 17
SHEET 12 16 C408 CAB-MFR CONN (OPTIONS)
SW12 DPF SWITCH
(LT GRAY) 2540 BLK 2730 BLK
2930 BLK CAB-MFR HARN CONN 2 J2B 15 SHEET 13
SHEET 12 2550 BLK SP282090 BLK
AUX CTRLR C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
SW1 BRAKE SWITCH
2830 BLK SP47 2900 BLK 1 2900 BLK
SHEET 17
SW6 BKT POSITION SWITCH
2700 BLK 2770 BLK
SHEET 12 SHEET 17
SW9 TRAVEL CONTROL SWITCH C355 FUEL HARN (PWR BOB/AC)
2785 BLK 2200 BLK
SHEET 17 SHEET 11
C126 HORN C425 BRAKE
2620 BLK
SHEET 15 C103 C489
T16 RH REAR LIGHT B 2720 BLK
TAILGATE HARN MFR ACCESSORY
SHEET 14 2650 BLK
SP51 2600 BLK B SP6 2390 BLK 10 T1 T10
T20 BU ALARM 2600 BLK 2015 BLK
2640 BLK BATT GND SHEET 9 ENGINE
SHEET 15 2400 BLK 14 ALTERNATOR GROUND GROUND
C602 LH REAR LIGHT SHEET 9
LEFT TAILGATE FANS GND
2610 BLK 2405 BLK 14
SHEET 15 SHEET 9
C603 RH REAR LIGHT RIGHT TAILGATE FANS GND
2630 BLK 2455 BLK
SHEET 15 SHEET 17 2300 BLK
T18 LH REAR LIGHT
C423 BKT POSITION SOLENOID SP27
2710 BLK
SHEET 7
C426 REMOTE RUN, ACD
SHEET 8 2715 BLK Printable Version Click Here
C169 ENGINE CAN
SHEET 15 2045 BLK SHEET 16
2290 BLK WIRING SCHEMATIC
FRC1 REAR LIGHT RELAY D4 COMPRESSOR DIODE
SHEET 9 2295 BLK 18
TAILGATE FANS RELAY GND
(SCPA MACHINE)
2115 BLK SP55 2105 BLK
SHEET 15
FRC1 FRONT LIGHT RELAY
2055 BLK
T870 (S/N ASWT11001 - ASWT11601)
SHEET 5
FRC1 SWITCHED POWER RELAY
2030 BLK
(S/N B3BZ11001 - B3BZ11129)
SHEET 16
FRC1 HVAC RELAY
SHEET 9 2005 BLK Sheet 6 of 18
FRC1 STARTER RELAY
SHEET 15
2120 BLK (PRINTED DECEMBER 2016)
FRC1 FRONT LIGHT RELAY
Printed In U.S.A. 7222673 (B)
565 of 1052
 J1B
GWY CTRLR
C408
(BLACK)
CAB-MFR HARN CONN 1
CAN BUS
8 9260 PUR 9230 PUR SP31 9250 PUR SP19 9220 PUR 4 9220 PUR SP18 9410 PUR SP39 9430 PUR SP35 9450 PUR 9460 PUR 4
CAN LO C479
9 9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT SP20 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
RE016 SP30 SP17 SP38 SP34 RE019
120 OHM 120 OHM
0.5 W 0.5 W
RESISTOR RESISTOR
J5 9440 PUR 4
DRIVE CTRLR C503
9340 PUR/WHT 2 RIGHT DELUXE PANEL
9290 PUR 22
9190 PUR/WHT 12
1830 RNG/WHT 1
SHEET 5 C450
2070 BLK 2
SHEET 6 RIGHT JOYSTICK
9320 PUR/WHT 3 SHEET 14
9420 PUR 4

1840 RNG/WHT 1
SHEET 5 C449
2080 BLK 2
SHEET 6 LEFT JOYSTICK
J2B 9300 PUR/WHT 3
SHEET 14
AUX CTRLR 9400 PUR 4
J2B C426 9280 PUR 8
AUX CTRLR Remote Run Tool, ACD
9180 PUR/WHT 9
14 9500 PUR/WHT A
CAN HI
20 9600 PUR B
CAN LO

Printable Version Click Here

J1B
GWY CTRLR
WIRING SCHEMATIC
21 3090 LBL D
REMOTE RUN KEY (SCPA MACHINE)
C
SHEET 5
1735 RNG/WHT
1165 RED/WHT
E
F
SWITCHED POWER T870 (S/N ASWT11001 - ASWT11601)
SHEET 4 UNSWITCHED POWER
SHEET 6
2710 BLK G
GROUND (S/N B3BZ11001 - B3BZ11129)
Printed In U.S.A. Sheet 7 of 18
(PRINTED DECEMBER 2016)
7222673 (B)

566 of 1052
 J7A
ECU CNTRLR

47
ENGINE CAN BUS SP81 SP90
SP67 SP71 SP70
C121
DOSING CONTROL UNIT

65
CAN LO
9200 PUR 9215 PUR 9415 PUR 9210 PUR 9265 PUR 9275 PUR 9245 PUR 120 Ohm Terminator
48 9100 PUR/WHT 9115 PUR/WHT 9315 PUR/WHT 9110 PUR/WHT SP68 9165 PUR/WHT SP72 9175 PUR/WHT SP69 9145 PUR/WHT 66 Resistor internal to Controller
CAN HI
RE014 SP82 SP91
120 OHM
0.5 W
RESISTOR
J1B
GWY CTRLR C163
NOx PRETREATMENT
9205 PUR 20
9105 PUR/WHT 14 9295 PUR 3
9195 PUR/WHT 4
2835 BLK 2
2875 BLK 5
1

SHEET 10 2870 BLK

NOx GROUND SP78 C164
NOx POST TREATMENT

2815 BLK 2
9285 PUR 3
9185 PUR/WHT 4
5
1635 RNG/WHT 1

1525 RNG 1645 RNG/WHT

SHEET 5
SP76
SCR INTERCONNECT
C161
DEF TANK
1640 RNG/WHT 4
C169
9225 PUR 1
ENGINE CAN
9125 PUR/WHT 2
1 1725 RNG/WHT 3
SHEET 5 SHEET 10 2825 BLK
2 2715 BLK SHEET 6
C121
3
4
9155 PUR/WHT
9255 PUR
DOSING CONTROL UNIT WIRING SCHEMATIC
82 Printable Version Click Here
5 9720 PUR/WHT
6 9820 PUR 60 (SCPA MACHINE)
T870 (S/N ASWT11001 - ASWT11601)
(S/N B3BZ11001 - B3BZ11129)
Sheet 8 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222673 (B)

567 of 1052
 FRC1
+12V STARTER RELAY - M
PWR 30
ENGINE C111
MFR-BCT HARN CONN
STARTER
1030 RED
SHEET 4 87 8200 TAN A 8220 TAN S M
B SHEET 4
3560 LBL B 3560 LBL R
GND 85 86 8210 TAN C 1015 RED
SHEET 6 2005 BLK SHEET 5 1800 RNG/WHT
FUSE 12
7 8210 TAN B
22 ALTERNATOR G
3560 LBL 1800 RNG/WHT
C405 EXCITATION
2150 BRN B GND 2015 BLK
SHEET 6 AIR FILTER SHEET 6
16 3150 LBL A SIG SWITCH (NC) ENGINE GROUND TERMINAL
J1A
GWY CTRLR FRC1
TAILGATE FANS
FUSE 15 A
25 3105 LBL 18 RELAY - C
12 3100 LBL 18 C119
C104 LEFT TAILGATE
87 A B C171
TAILGATE FANS CONN FAN CONN
TAILGATE FANS RELAY PWR 1105 RED/WHT 10 87A 8110 TAN 14 1 8110 TAN 14 8125 TAN 14 A
30 LEFT
SHEET 4 TAILGATE 2400 BLK 14 2 2400 BLK 14 B
2295 BLK 18 85 86 FANS GND SHEET 6 8105 TAN 14 3 8105 TAN 14 FUSE 15 A
TAILGATE FANS RELAY GND
RIGHT 2405 BLK 14 4 2405 BLK 14 C113
9 8100 TAN 18 SHEET 6
TAILGATE SHEET 6 C172 RIGHT TAILGATE
J1B A B FAN CONN
C355 FANS GND
GWY CTRLR A
FUEL HARN 8135 TAN 14
C406
B
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
2180 BRN D 2180 BRN B GND (30 - 270 OHM)
10 SHEET 6
3690 LBL
C428
C120 (LT GRAY)
SHEET 6 ENGINE C114 INTAKE HEATER
2430 BRN 18 2 CAB-MFR HARN CONN 2 +12V CONTACTOR
TEMP HAND THROTTLE
18 1 T29 PWR FUSE 150 A
3110 LBL 18 SENSOR SHEET 13 5690 YEL 7 5690 YEL C +5V PWR 30
(950-4400 OHM) 1060 RED 1 2 1065 RED/WHT 87 8515 TAN SP77 8500 TAN
6 T14
3690 LBL 3690 LBL A
SIG T26 T27 8510 TAN 85 86 1445 RED/WHT
2690 BRN 8 2690 BRN B GND
4 8007 TAN SHEET 4
SHEET 6 D 8505 TAN T31
E
J7A F
ENG ECU CTRLR
8020 TAN SP74
SHEET 10
19 8008 TAN
C100 Printable Version Click Here
9 3865 LBL 1 WATER IN FUEL SENSOR
SIG
34 2865 BRN 2 GND (FUEL FILTER) WIRING SCHEMATIC
56

C118
(SCPA MACHINE)
28 8013 TAN

35 8014 TAN 1511 RNG/WHT

ENG-CROSSOVER
1 TO C154 - Pin 1
T870 (S/N ASWT11001 - ASWT11601)
ENG-CROSSOVER SHEET 5 See Sheet 18 of 18
8013 TAN
8014 TAN
2 FREQ
3 TEMP
TO MAF - Pin 1
See Sheet 18 of 18
TO MAF - Pin 4
(S/N B3BZ11001 - B3BZ11129)
Sheet 9 of 18
See Sheet 18 of 18
3420 LBL 4 TO GLOW PLUG - ECU Pin 179
T42 See Sheet 18 of 18

(PRINTED DECEMBER 2016)

Printed In U.S.A. 7222673 (B)

568 of 1052
 DOSING CONTROL UNIT HOSE HEATER MAIN
1100 RED/WHT 30
87 8090 TAN
SHEET 4 T33
2975 BLK 85 86
DCU CASE GND

2915 BLK
C121
DOSING CONTROL UNIT

1230 RED/WHT SP62 1245 RED/WHT 5 93 8310 TAN

SHEET 4 1265 RED/WHT 6
C123
1255 RED/WHT 73 67 HOSE 1 HEATER

2310 BRN
1275 RED/WHT 51 68 7998 WHT SP87 1
8120 TAN
2
89 8320 TAN
2880 BLK SP63 2925 BLK 1
SHEET 6 90 7999 WHT
C120 SCR-MFR CONN SHEET 8 2825 BLK 2935 BLK 2 HOSE 1 HEATER
2945 BLK 7 72 8340 TAN SP88 8330 TAN 30

8140 TAN
87 2955 BLK SP86
Nox Ground 2870 BLK 2855 BLK 29
SHEET 8 C124
2145 BRN 85 86 HOSE 2 HEATER
8020 TAN 22
94 1
SHEET 9 8550 TAN
8240 TAN 2
53 2135 BRN SP85
C155
1 2170 BRN 75 HOSE 2 HEATER
TANK HEATING VALVE

8150 TAN
4 8540 TAN 92 49 SP89 30
8260 TAN 8250 TAN
87 2965 BLK
C156 C125

2985 BLK
85 86 HOSE 3 HEATER
1 8850 WHT 80 2140 BRN
REDUCTION AGENT
50 8560 TAN 1
METERING VALVE 2 8950 BLK 58
2165 BLK 2
59 8350 TAN
C157
1 8900 TAN 83 HOSE 3 HEATER
CATALYST TEMPERATURE
2 61 27 8370 TAN SP61
SCR INLET 2025 BRN 8360 TAN 30
87
C158
1 62 85 86
8520 TAN 2125 BRN
CATALYST TEMPERATURE
SCR OUTLET 2 2160 BRN 84 28 8600 TAN
C159
1 8800 TAN 31 C122
ENVIRONMENTAL TEMPERATURE SUPPLY MODULE
2 2050 BRN 9
4 1690 RNG/WHT 11 Printable Version Click Here
HEATER BATT+
C160 3 12

CATALYST TEMPERATURE
1 8530 TAN 18 TXL 34
55
8650 TAN
1695 RNG/WHT 3
HEATER SIGNAL
WIRING SCHEMATIC
DOC INLET 12 PUMP MOTOR BATT +
2 2075 BRN 18 TXL
76 8700 TAN 2
PUMP MOTOR CONTROL SIGNAL (SCPA MACHINE)
54 4
2095 BRN
77 1680 RNG/WHT 5
PUMP MOTOR GND
T870 (S/N ASWT11001 - ASWT11601)
PURGING PUMP BATT +
78 8750 TAN
6
PURGING PUMP SIGNAL (S/N B3BZ11001 - B3BZ11129)
17 10

39
1685 RNG/WHT
3000 LBL
9
PRESSURE SENSOR BATT+
Sheet 10 of 18
PRESSURE SENSOR SIGNAL
40 8
2085 BRN PRESSURE SENSOR GND (PRINTED DECEMBER 2016)
Printed In U.S.A. 7222673 (B)
569 of 1052
 HYDRAULICS
C425

B C308
BRAKE
4200 LGN A 4200 LGN A SOLENOID TRACK 2 SPEED
2200 BLK C 2200 BLK B 9.8 OHM ADAPTER (SEE
SHEET 6 ADDITIONAL
12 V
WHEEL 2 SPD ADP HARNESS 7159366 OPTIONS DWG)
TRACK 2 SPD ADP HARNESS 7214627
TRACK SINGLE SPD BRAKE ADP HARNESS 7234968

C108
2220 BRN B HYDRAULIC
GND
SHEET 6 TEMPERATURE
32 3220 LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320 LBL A SIG HYDRAULIC OIL
GWY CTRLR 2320 BRN B GND FILTER SWITCH (NC)
SHEET 6

C446
18 2910 BRN 2 GND HYDRAULIC
4010 LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410 BRN B GND HYDRAULIC LOCK
4410 LGN A SIG SOLENOID
9.8 OHM 12 V
C105
2190 BRN B GND HYDRAULIC
SHEET 6
3190 LBL C SIG CHARGE
5190 YEL A +8V PWR PRESSURE
0.5-7.5V
4200 LGN

19 13 1 23 6
J1B Printable Version Click Here
GWY CTRLR

WIRING SCHEMATIC
C418
J2A
AUX CTRLR
18 2330 BRN 2
1
GND
SIG
FRONT ROD
SOLENOID (MALE)
(SCPA MACHINE)
4330 LGN
3.3 OHM PWM
C419
T870 (S/N ASWT11001 - ASWT11601)
1 2 GND
2340 BRN
4340 LGN 1 SIG
FRONT BASE
SOLENOID (FEMALE) (S/N B3BZ11001 - B3BZ11129)
3.3 OHM PWM
Sheet 11 of 18
19 13 (PRINTED DECEMBER 2016)
J2B
Printed In U.S.A. AUX CTRLR
7222673 (B)

570 of 1052
SHEET 5
1940 RNG/WHT
T13
BUZZER (+)

LEFT PANEL
BUZZER
CAB DISPLAY C499
Press To Operate Loader
7040 WHT
C479 (PTOL)
T2
LEFT PANEL (BLACK) 1930 RNG/WHT 1
BUZZER (-) SHEET 5 SWITCHED POWER
10 C408 2940 BLK 3
7040 WHT BUZZER SHEET 6 GROUND
(BLACK)
2920 BLK 2 CAB-MFR HARN CONN 1
SHEET 6 GROUND
1960 RNG/WHT 1440 RED/WHT 1
SHEET 5 SHEET 4 UNSWITCHED POWER 20 3030 LBL 1 3030 LBL 2
PTOL OUTPUT
SW9 1620 RNG/WHT 5 SWITCHED POWER
SHEET 5 19 2380 BRN 12 2380 BRN 4
TRAVEL CONTROL PTOL LED
SWITCH (OPTIONAL) 3400 LBL 11 LEFT BLINKER INPUT J1A
SHEET 17
GWY CTRLR
5 6 SHEET 17
3500 LBL 8 C500
RIGHT BLINKER INPUT RIGHT PANEL - KEY SWITCH
4
2700 BLK 2 3 3650 LBL 7 24 8130 TAN 2 8130 TAN 2
SHEET 6 TRAVEL CONTROL INPUT START
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610 LBL 4 5
SHEET 5 1775 RNG/WHT 6
2930 BLK C480 J1B 22 3040 LBL 14 4
SHEET 6 LEFT PANEL (GRAY) 3040 LBL RUN/ENTER SWITCH
GWY CTRLR
3620 LBL 12
SHEET 13 DOOR SIGNAL
11 1950 RNG/WHT 5
SHEET 5 SWITCHED POWER
10 1420 RED/WHT 1
SHEET 4 UNSWITCHED POWER
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
8
SW12
DESOX INHIBIT SWITCH 7 C503
(OPT KIT) 6 RIGHT PANEL DELUXE DISPLAY
1700 RNG/WHT 7 9 8050 TAN 4 1590 RNG/WHT 5
SHEET 5 SHEET 5 SWITCHED POWER
1705 RNG/WHT 10 8 8055 TAN 5
SHEET 5 DESOX INHIBIT LAMP 1240 RED/WHT 1
SHEET 4 UNSWITCHED POWER
2065 BLK 2 4 8070 TAN 9
SHEET 6 DESOX INHIBIT 2250 BLK 3
1 SHEET 6 GROUND
1 6
3 8060 TAN

WIRING SCHEMATIC
Printable Version Click Here
(SCPA MACHINE)
T870 (S/N ASWT11001 - ASWT11601)
(S/N B3BZ11001 - B3BZ11129)
Sheet 12 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222673 (B)

571 of 1052
 C438
CAB
(DK GRAY)
CAB-MFR HARN CONN 3
* DLX CAB HARN 7253375 ONLY
1850 RNG/WHT 2
(NOT IN STD CAB HARN) * C212
POWER
SHEET 5 1850 RNG/WHT
SOCKET
2795 BLK 1 GND
1375 RED/WHT 2 +12V PWR
C408
(BLACK)
CAB-MFR HARN CONN 1

1370 RED/WHT 7 1370 RED/WHT SP45

*
1390 RED/WHT
T37
DOME LIGHT (+)
SHEET 4
DOME
SP41 2010 BLK LIGHT
C129
CAB ACCESSORY
1210 RED/WHT A +12V BATT PWR * T38
DOME LIGHT (-)
1580 RNG/WHT 5 1580 RNG/WHT SP8 1865 RNG/WHT B +12V SW PWR
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 17
1885 RNG/WHT SHEET 17
SP44 2210 BLK SHEET 17
2730 BLK 11 2730 BLK 2885 BLK
SHEET 6 SHEET 17
2060 BLK SHEET 14
C428
(LT GRAY) * C667
DOOR HARNESS
CAB-MFR HARN CONN 2 (SEE ADDITIONAL
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
WIPER SWITCH, MOTOR SWITCHED POWER
3620 LBL 4
SHEET 12 DOOR SIGNAL
1400 RED/WHT 5
SHEET 4 DOOR UNSW PWR
6
C482 SEATBAR 2840 BLK 2
WIPER MOTOR GROUND
J1B
GWY CTRLR SHEET 6
2370 BRN 4 2370 BRN A GND SENSOR 7310 WHT 3
WASHER SIGNAL

11 3370 LBL 5 3370 LBL B SIG

24 5100 YEL SP13 5370 YEL 3 5370 YEL C +5V PWR

+5V
Printable Version Click Here
HARNESS WASHER PUMP
SHEET 9 5690 YEL 7253378
WIRING SCHEMATIC
(SCPA MACHINE)
* C252 C253
PWR
A 7310 WHT 1 WASHER
MOTOR
T870 (S/N ASWT11001 - ASWT11601)
2845 BLK B 2845 BLK 2 GND (S/N B3BZ11001 - B3BZ11129)
Sheet 13 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222673 (B)
572 of 1052
 SW4 J5
HAND/FOOT DRIVE CTRLR
(ACS)
H/ISO 33
(SJC, AWS) 34
SWITCH

CONTROLS
SHEET 5
1785 RNG/WHT 2 1
3 40 SP11
+5V 5890 YEL
2060 BLK 5 6
SHEET 13
4
C438 23
J5 (DK GRAY) 24
DRIVE CTRLR CAB-MFR HARN CONN 3

6 4235 LGN 7 4235 LGN C536

5810 YEL 2 C543 A22 PUMP HARNESS
16 4275 LGN 8 4275 LGN
29 SP56 4 2810 BRN 1
4 9 2890 BRN 2810 BRN GND
4550 LGN 4550 LGN RIGHT
8 3810 LBL 3 3810 LBL 3 SIG SWASHPLATE
1710 RNG/WHT 1 1710 RNG/WHT 2 +12V PWR
SHEET 5
C103 C537
TAILGATE HARN 5860 YEL 2 C542
T19 TERMINAL (+)
36 7100 WHT C 7100 WHT 2860 BRN 4 2860 BRN 1 GND LEFT
BACK UP 7 3860 LBL 3 3860 LBL 3 SIG SWASHPLATE
2650 BLK ALARM 1770 RNG/WHT 1 1770 RNG/WHT 2 +12V PWR
SHEET 6 SHEET 5
T20 TERMINAL (-) C501 C546
43 4260 LGN 1 4260 LGN 1
RIGHT FORWARD DRIVE
42 2660 BRN 2 2660 BRN 2
C460
1 1830 RNG/WHT 1 +12V PWR
C547
C450 2 2070 BLK 2 GND 44 4250 LGN 3 4250 LGN 1
RIGHT JOYSTICK
RIGHT RIGHT REVERSE DRIVE
3 9560 PUR/WHT 3 CAN HI HANDLE 45 2650 BRN 4 2650 BRN 2
4 9660 PUR 4 CAN LO
C545
31 4280 LGN 5 4280 LGN 1
C459 41 2680 BRN 6 2680 BRN 2 LEFT REVERSE DRIVE
1 1840 RNG/WHT 1 +12V PWR

C449 2 2080 BLK 2 GND C544

LEFT JOYSTICK 3 9540 PUR/WHT 3 CAN HI
LEFT 21 4270 LGN 7 4270 LGN 1
11 8 2670 BRN 2 LEFT FORWARD DRIVE
HANDLE 2670 BRN
4 9640 PUR 4 CAN LO

SUSP SEAT JOYSTICK HARNESS 7163706 C474

26 4210 LGN A BRAKE CONN
USED WITH ROADLIGHT KIT

C421
J1A 10 2980 BRN 3 GND Printable Version Click Here
GWY CTRLR 4980 LGN 1 SIG TILT SPOOL LOCK
2 7.8 OHM 12V
WIRING SCHEMATIC
C422
2 2990 BRN 3 GND
LIFT SPOOL LOCK
(SCPA MACHINE)
4990 LGN 1 SIG
2
7.8 OHM 12V
T870 (S/N ASWT11001 - ASWT11601)
(S/N B3BZ11001 - B3BZ11129)
7 5
J1B
Sheet 14 of 18
GWY CTRLR
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222673 (B)
573 of 1052
 C434-1
2735 BLK B GND LEFT FRONT
C408
6100 PNK A SIG WORK LIGHT
(BLACK)

LIGHTS CAB-MFR HARN CONN 1 37.00 Watts

C434-2
2765 BLK 9 2765 BLK SP14 2750 BLK B GND
SHEET 6 LEFT FRONT
6110 PNK A SIG WORK LIGHT
50.00 Watts

C435-1
6000 PNK 8 6000 PNK SP15 6120 PNK A SIG RIGHT FRONT
FRC1 WORK LIGHT
2760 BLK B GND
FRONT WORK 37.00 Watts
LIGHTS RELAY - J
C438 C435-2
(DK GRAY) 6130 PNK A SIG
SHEET 4 1350 RED/WHT 30 CAB-MFR HARN CONN 3 RIGHT FRONT
87 6610 PNK 2705 BLK B GND WORK LIGHT
50.00 Watts
13 6610 PNK SP64
SHEET 6 2120 BLK 85 86

FRC1

6630 PNK
FRONT WORK
LIGHTS RELAY - K C103
+12V TAILGATE HARN C603
PWR 2610 BLK 2 GND
1330 RED/WHT 30 SHEET 6 RIGHT REAR
SHEET 4 87 6340 PNK SP10 6310 PNK A 6310 PNK SP49 6320 PNK 1 SIG
TAIL LIGHT
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK 2 LEFT REAR
GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL
Printable Version Click Here

2620 BLK
T16 TERMINAL (-)
GND
WIRING SCHEMATIC
SHEET 6 RIGHT REAR

FRC1
6210 PNK SIG WORK LIGHT
(SCPA MACHINE)
REAR LIGHT T15 TERMINAL (+)
+12V RELAY - E
PWR 30 T17 TERMINAL (+)
T870 (S/N ASWT11001 - ASWT11601)
1320 RED/WHT
SHEET 4 6200 PNK H 6200 PNK SP96 6220 PNK
GND 85
87
86 SHEET 6 2630 BLK
SIG
GND
LEFT REAR
WORK LIGHT (S/N B3BZ11001 - B3BZ11129)
2045 BLK
SHEET 6 T18 TERMINAL (-)
Sheet 15 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222673 (B)

574 of 1052
 2440 BLK * C610
2 GND HVAC DUCT

HVAC
7440 WHT 1 SIG FAN

2560 BLK
* C483
C BLK
7420 WHT A DBL POTENTIOMETER
7425 WHT B (TEMP CONTROL
WHT SWITCH)
* DLX CAB HARN 7253375 ONLY C635
(NOT IN STD CAB HARN) * D SIG
2130 BLK C GND HEATER
SP48 7430 WHT A +12V PWR VALVE
B
E
F

FRC1
HVAC RELAY - B
C438
(DK GRAY)
*BLOWER
SW10

+12V CAB-MFR HARN CONN 3 SWITCH

PWR 30 OFF
1140 RED/WHT
SHEET 4 87 1500 RNG/WHT 10 1500 RNG/WHT 5 2
1
2030 BLK GND 85 86 4
SHEET 6 7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
3 7520 WHT 2 7.50 Amps Med BLOWER
7050 WHT MOTOR
SW11 7510 WHT 3 5.00 Amps Low
J1A
30 3050 LBL
SHEET 6
2745 BLK 11 2745 BLK SP16 *
AC SWITCH 2580 BLK 4
GWY CTRLR
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT SP40 7020 WHT 12
C630
* 3
THERMOSTAT

AC EVAPORATOR C350 2570 BLK 2 Printable Version Click Here

SWITCH B 7023 WHT 7020 WHT 1
A 7024 WHT WIRING SCHEMATIC
7025 WHT
C486
1 SIG
(SCPA MACHINE)
MAGNET CLUTCH
2290 BLK 2280 BLK
2 GND
(COMPRESSOR) T870 (S/N ASWT11001 - ASWT11601)
SHEET 6
D4
(S/N B3BZ11001 - B3BZ11129)
Sheet 16 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222673 (B)

575 of 1052
 # C607
C355
FUEL HARN
C428
(LT GRAY)
CAB-MFR HARN CONN 2 #
OPTIONS
DLX FUEL HARN 7266824 ONLY
SIG 1 4470 LGN E 4470 LGN 11 4470 LGN
POWER BOB
CLOSE GND 2 2470 BLK 2770 BLK B 2770 BLK
SHEET 6 4480 LGN (NOT IN STD FUEL HARN 7149219)
SW5
*POWER 2 1
# C606
2 2480 BLK
BOBTACH
SWITCH 5
3
4 * DLX CAB HARN 7253375 ONLY
GND 6
POWER BOB
OPEN
SIG 1 4480 LGN F 4480 LGN 10 (NOT IN STD CAB HARN)
6010 PNK 13 6010 PNK

1380 RED/WHT
1550 RNG/WHT 12 1550 RNG/WHT
SHEET 5

C438
(DK GRAY)
CAB-MFR HARN CONN 3 1200 RED/WHT

C411
B
SHEET 4
1410 RED/WHT 1 1410 RED/WHT 1430 RED/WHT X
L
* T3
FLASHER
LEFT HANDLE CONN
C SHEET 12 3500 LBL
(FLASHER) 5 WAY D1
A 6515 PNK 6500 PNK 6 6500 PNK 6530 PNK
*BEACON
SW2

6570 PNK
(SEE ADDITIONAL E
OPTIONS DWG) D 6415 PNK 6400 PNK 3 6400 PNK
D2 6430 PNK SWITCH
3400 LBL 2725 BLK 6
C103 SHEET 12 *HAZARD
SW3
2
1
6700 PNK
4
1
5
2
TAILGATE HARN 3
SWITCH 4 3
5
EURO TAIL LIGHTS E 6410 PNK (PINS 3 & 6 2850 BLK
INTERNALLY 6
D
(SEE ADDITIONAL
OPTIONS DWG)
6510 PNK
INSULATED) * C670
E
2780 BLK 4 2780 BLK 2780 BLK 2420 BLK D
C423 SHEET 6 BEACON/FLASHER
3 6440 PNK F EXTERIOR HARNESS
BUCKET SIG A 4450 LGN D3 4455 LGN 5 4455 LGN 1
4
2 * SW6
BUCKET 6540 PNK B (SEE ADDITIONAL
OPTIONS DWG)
POSITION 2830 BLK 5 POSITION C
SOLENOID GND B 2450 BLK 2455 BLK SHEET 6 SWITCH A
SHEET 6 6
9.8 OHM
C408
(BLACK) * C676

LEFT HANDLE C412

CAB-MFR HARN CONN 1 SHEET 6
2785 BLK
C126
B GND LEFT
*+
C279
1 7820 WHT
RADIO CONN
3
C277
(HORN) 2 WAY
(SEE ADDITIONAL
B
A 1460 RED/WHT
7210 WHT 13 7210 WHT A SIG HORN SPEAKER
-
2 7830 WHT 4
* 1
OPTIONS DWG) SHEET 4 2
C497
SJC
RIGHT
*-
C278
2 7810 WHT 6 3
AIR RIDE
SEAT
5 7200 WHT C SPEAKER 1 7800 WHT 5 1510 RNG/WHT 4 PWR
HORN/BLINKER SHEET 13
4 6420 PNK A + 1885 RNG/WHT 1 2210 BLK 5 GND
(SEE ADDITIONAL SHEET 13 SHEET 13
J2A 3 6520 PNK B OPTIONS DWG) 2885 BLK 2 6
SHEET 13
AUX CTRLR
C415
26 B HIGH FLOW
2460 BRN
4460 LGN A
GND
SIG
SOLENOID
7.5 OHM 12 V
WIRING SCHEMATIC
Printable Version Click Here
J2B
AUX CTRLR
26 (SCPA MACHINE)
C441
TRACK 2 SPEED
T870 (S/N ASWT11001 - ASWT11601)
J1A 26 2350 BRN 2 GND TWO SPEED
GWY CTRLR 4350 LGN 1 SIG SOLENOID
5.1 OHM 12 V
ADAPTER
(SEE ADDITIONAL (S/N B3BZ11001 - B3BZ11129)
OPTIONS DWG)
J1B
GWY CTRLR
26
Sheet 17 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7222673 (B)
576 of 1052
 TO C118 - Pin 4

SUPPLIED
See Sheet 9 of 18 PRE HEATER 179 J7B
ENG ECU CTRLR
(DOOSAN HARNESS)

C131
106 TEMPERATURE SENSOR 2 EXHAUST GAS

ENGINE
123 TEMP SENSOR
SENSOR RETURN 2
BEFORE TURBO

C151
1 EGR VREF3 164
C133

HARNESS
5 POSITION SIGNAL 116 194 TEMPERATUR SENSOR 4
EGR VALVE INTAKE
DC MOTOR 3 POSITION RETURN 172 169 SENSOR RETURN 4 MANIFOLD TEMP
6 H BRIDGE POS 192
2 H BRIDGE NEG 193

C149 TO C118 - Pin 33

1 COOLANT TEMP SENSOR 109 See Sheet 9 of 18
COOLANT TEMP 4 INTAKE
SENSOR 2 COOLANT RETURN 145 THROTTLE
120 VREF3 THROTTLE POSITION 1
C148 137 POSITION SENSOR GRD 3
1 FUEL TEMPERATURE SENSOR 110 TO C118 - Pin 2 2
FUEL TEMP
SENSOR 2 FUEL RETURN 146 See Sheet 9 of 18
C136
C147 165 VREF3 OIL PRESSURE
1 131 OIL PRESSURE &
ENGINE BLOCK SENSOR SIGNAL 111 OIL PRESSURE SENSOR TEMPERATURE
ACCELEROMETER 1 2 SENSOR RETURN 130 148 SENSOR
RETURN GRD
SHIELD 128
104 OIL TEMPERATURE SENSOR
C146
1 SENSOR SIGNAL 132
ENGINE BLOCK
ACCELEROMETER 2 2 SENSOR RETURN 133
SHIELD 129

C145
CRANKSHAFT CRANK SENSOR POS 160
POSITION 136
SENSOR
CRANK SENSOR NEG

C144
C138 Printable Version Click Here
1 SENSOR RETURN 147
141 VREF2 INTAKE PRESSURE B
CAM SHAFT 2 159
SENSOR
3
POS SENSOR
VREF1 CAM TO C118 - Pin 1
112 INTAKE PRESSURE SENSOR A
INLET TEMP WIRING SCHEMATIC
167 INTAKEPRESSURE RETURN D PRESSURE
See Sheet 9 of 18
C143
135
SENSOR
(SCPA MACHINE)
1 RAIL PRESSURE SENSOR
RAIL PRESSURE
SENSOR
2 SENSOR RETURN 119
C139
T870 (S/N ASWT11001 - ASWT11601)
3 VREF 1 SENSOR 138
127
C141 126
FUEL INJECTOR HSDA
FUEL INJECTOR LSD1A CYL 1 (S/N B3BZ11001 - B3BZ11129)
FUEL INJECTOR HSDB 151
CYL 3
FUEL INJECTOR LSD1B 175
150
C140 Sheet 18 of 18
FUEL INJECTOR HSDB
C142 174 CYL 2
FUEL INJECTOR LSD2B
FUEL INJECTOR HSDA 103 (PRINTED DECEMBER 2016)
CYL 4 125 C154
Printed In U.S.A. FUEL INJECTOR LSD2A
177 PWM 2 7222673 (B)
INLET METERING
TO C118 - Pin 1 1 VALVE
See Sheet 9 of 18
577 of 1052
 CONNECTOR ASSIGNMENTS
NUM NUM NUM NUM
CONN DESCRIPTION OF SHEET CONN DESCRIPTION OF SHEET CONN DESCRIPTION OF SHEET CONN DESCRIPTION OF SHEET
PINS PINS PINS PINS
C100 WATER IN FUEL SENDER 2 9 C279 LEFT SPEAKER 2 17 C489 MFR ACCESSORY 2 5,6 SW5 POWER BOBTACH SWITCH 6 17
C103 TAILGATE HARNESS 8 6,14,15,17 C308 BRAKE SOLENOID 2 11 C497 SJC HORN/BLINKER 3 17 SW6 BUCKET POSITION SWITCH 6 17
C104 TAILGATE FANS 4 9 C350 AC EVAPORATOR SWITCH 2 16 C499 PTOL 4 12 SW9 TRAVEL CONTROL SWITCH 6 12
C105 HYD CHARGE PRESSURE 3 11 C355 FUEL HARNESS 6 9,17 C500 RH KEY SWITCH 6 12 SW10 BLOWER SWITCH 5 16
SENSOR
C108 HYD TEMPERATURE SENDER 2 11 C405 AIR FILTER SWITCH 2 9 C501 A22 PUMP HARN CONN 8 14 SW11 AC SWITCH 3 16
C111 MFR-BCT ENG HARN CONN 3 9 C406 FUEL SENDER 2 9 C503 RH DLX PANEL 6 7,12 SW12 DPF SWITCH 10 12
C112 HYD OIL FILTER SWITCH 2 11 C408 CAB-MFR HARN CONN(BLK) 14 4,6,7,12,13, C536 A22 PUMP HARN - R SWASH 4 14 RC1 FRONT WORK-LIGHTS RELAY 4 15
15,17
C113 RIGHT TAILGATE FAN CONN 2 9 C411 LEFT HANDLE 5 WAY 5 17 C537 A22 PUMP HARN - L SWASH 4 14 RC2 FRONT WORK-LIGHTS RELAY 4 15
C114 HAND THROTTLE 6 9 C412 LEFT HANDLE 2 WAY 2 17 C542 LEFT SWASH PLATE 3 14 T1 BATT GROUND 1 6

C118 ENG-CROSSOVER 4 9 C415 HIGH FLOW SOLENOID 2 17 C543 RIGHT SWASH PLATE 3 14 T2 BUZZER GROUND 1 12
C119 LEFT TAILGATE FAN CONN 2 9 C418 FRONT ROD 2 11 C544 LEFT FORWARD DRIVE 2 14 T3 FLASHER 2 17
C120 ENGINE TEMP SENSOR 2 9 C419 FRONT BASE 2 11 C545 LEFT REVERSE DRIVE 2 14 T4 MEGAFUSE 1 4
C121 DOSING CONTROL UNIT 94 8,10 C420 HYD LOCK 2 11 C546 RIGHT FORWARD DRIVE 2 14 T6 BATT GROUND 1 6
C122 SUPPLY MODULE 12 10 C421 TILT SPOOL LOCK 3 14 C547 RIGHT REVERSE DRIVE 2 14 T8 BATT GROUND 1 6
C123 HOSE 1 HEATER 2 10 C422 LIFT SPOOL LOCK 3 14 C602 LEFT REAR TAIL LIGHT 2 15 T10 ENGINE SYSTEM GROUND 1 6
C124 HOSE 2 HEATER 2 10 C423 BUCKET POSITION 2 17 C603 RIGHT REAR TAIL LIGHT 2 15 T13 BUZZER POWER 1 12
C125 HOSE 3 HEATER 2 10 C425 BRAKE SOLENOID 3 11 C606 POWER BOBTACH OPEN 2 17 T14 PRE HEATER 1 9
C126 HORN 2 17 C426 CAN (Remote Start Tool, ACD) 7 7 C607 POWER BOBTACH CLOSE 2 17 T15 RIGHT REAR WORK LIGHT(+) 1 15
C129 CAB ACCESSORY 3 13 C428 CAB-MFR HARN CONN(LT GRY) 14 5,6,9,13,17 C610 HVAC DUCT FAN 2 16 T16 RIGHT REAR WORK LIGHT(-) 1 15
C155 TANK HEATING VALVE 4 10 C434-1 LEFT FRONT LIGHT (37W) 2 15 C611 BLOWER MOTOR 4 16 T17 LEFT REAR WORK LIGHT (+) 1 15
C156 REDUCTION AGENT METERING 2 10 C434-2 LEFT FRONT LIGHT (50W) 2 15 C630 THERMOSTAT 3 16 T18 LEFT REAR WORK LIGHT (-) 1 15
VALVE
C157 CATALYST TEMP SCR INLET 2 10 C435-1 RIGHT FRONT LIGHT (37W) 2 15 C635 HEATER VALVE 6 16 T19 BACKUP ALARM 1 14
C158 CATALYST TEMP SCR OUTLET 2 10 C435-2 RIGHT FRONT LIGHT (50W) 2 15 C667 DOOR HARNESS 6 13 T20 BACKUP ALARM (GND) 1 14

C159 ENVIRONMENTAL TEMP 2 10 C438 CAB-MFR HARN CONN(DK GRY) 14 13,14,15,16, C670 EXTERIOR BEACON HARNESS 6 17 T26 FUSE 150 AMP 1 9
17
C160 CATALYST TEMP DOC INLET 2 10 C441 TWO SPEED SOLENOID 2 17 C676 RADIO 6 17 T27 PRE HEATER CONTACTOR PWR 1 9
C161 DEF TANK 4 8 C446 HYDRAULIC FAN SOLENOID 2 11 FRC1 FUSE RELAY CENTER 112 4,5,9,15,16 T29 BATTERY 1 9
C163 NOx PRETREATMENT 5 8 C449 LEFT JOYSTICK(CAB HARN) 4 7,14 J1A GATEWAY CONTROLLER 34 5,9,11,12, T31 PREHEATER 1 9
14,15,16,17
C164 NOx POST TREATMENT 5 8 C450 RIGHT JOYSTICK(CAB HARN) 4 7,14 J1B GATEWAY CONTROLLER 26 4,6,7,8,9,11 T32 ECU CASE GND 1 6
12,13,14,17
C169 ENGINE CAN DIAGNOSTIC 6 8 C459 LEFT HANDLE 4 14 J2A AUX CONTROLLER 34 11,17 T33 DCU CASE GND 1 10

C171 INLINE FAN FUSE LEFT 2 9 C460 RIGHT HANDLE 4 14 J2B AUX CONTROLLER 26 4,5,6,7,11 T37 DOME LIGHT + 1 13
17
C172 INLINE FAN FUSE RIGHT 2 9 C474 BRAKE (ROAD KIT) 1 14 J5 DRIVE CONTROLLER 48 4,5,6,7,14 T38 DOME LIGHT - 1 13

C212 POWER SOCKET 2 13 C479 LEFT PANEL(BLACK) 12 7,12 J7A ENG ECU CONTROLLER (BCT) 58 5,6,8,9 T42 PREHEATER FDBK 1 9

C252 WASHER ADAPTER INTMD 2 13 C480 LEFT PANEL(GRAY) 12 12 SW1 BRAKE SWITCH 6 12

C253 WASHER PUMP 2 13 C482 SEATBAR SENSOR 3 13 SW2 BEACON SWITCH 6 17

C277 AIR RIDE SEAT 6 17 C483 TEMP CONTROL SWITCH 3 16 SW3 HAZARD SWITCH 6 17
C278 RIGHT SPEAKER 2 17 C486 AC COMPRESSOR 2 16 SW4 HAND/FOOT, H/ISO SWITCH 6 14

WIRING SCHEMATIC
Printable Version Click Here
(SCPA MACHINE)
T870 (S/N ASWT11602 - ASWT11946)
(S/N B3BZ11130 - B3BZ11141)
Printed In U.S.A.
Sheet 1 of 18
(PRINTED DECEMBER 2016)
7281093
578 of 1052
 J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER)
PIN FUNCTION PIN FUNCTION
PIN FUNCTION PIN FUNCTION A-1 FRONT AUX (F) RETURN (BASE) B-1
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS
A-2 B-2 UNSW BATT
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT
A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-3 HVAC RELAY - B B-3 UNSW BATT
A-4 RIGHT BLINKER RELAY B-4
A-4 SWITCHED PWR OUT RELAY - A B-4 ENGINE RUN SIGNAL
A-5 HORN RELAY B-5
A-5 FRONT LIGHT RELAY - J B-5 LIFT SPOOL LOCK
A-6 B-6
A-6 B-6 TRACTION LOCK HOLD
A-7 B-7
A-7 STARTER RELAY - M B-7 TILT SPOOL LOCK
A-8 B-8 CAN LO 1
A-8 B-8 CAN LO 1
A-9 B-9 CAN HI 1
A-9 TAILGATE FANS OUT RELAY - C B-9 CAN HI 1
A-10 B-10
A-10 TILT SPOOL LOCK RETURN B-10 HAND THROTTLE
A-11 B-11
A-11 AC SENSE B-11 SEAT BAR
A-12 B-12
A-12 LEFT FAN FDBK RELAY - C B-12 FUEL LEVEL
A-13 B-13 FRONT AUX (F) (BASE)
A-13 B-13 BICS HYD LOCK HOLD
A-14 B-14 CAN HI 2
A-14 B-14 CAN HI 2
A-15 B-15 GROUND
A-15 B-15 GROUND P1
A-16 B-16 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2
A-17 B-17 RH PWM LO
A-17 REAR LIGHT RELAY - E B-17 GROUND P3, SENSOR
A-18 FRONT AUX (M) RETURN (ROD) B-18 RH PWM SIG
A-18 HYD FAN RETURN B-18 ENGINE TEMP SENSOR
A-19 B-19 FRONT AUX (M) (ROD)
A-19 PTOL LED B-19 HYD FAN OUTPUT
A-20 B-20 CAN LO 2
A-20 PTOL SWITCH B-20 CAN LO 2
A-21 B-21 RH TRIGGER RETURN
A-21 SWITCHED PWR FDBK RELAY - A B-21 REMOTE RUN KEY
A-22 B-22 SWITCHED PWR
A-22 STATER FDBK RELAY - M B-22 RUN/ENTER
A-23 B-23 RH PWM HI
A-23 B-23 SENSOR SUPPLY 8V
A-24 B-24
A-24 START ENGINE B-24 SENSOR SUPPLY 5V
A-25 B-25
A-25 RIGHT FAN FDBK RELAY - C B-25
A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-26 TWO SPEED RETURN B-26 TWO SPEED COIL
A-27
A-27
A-28
A-28 REAR LIGHT FDBK RELAY - E
A-29
A-29
A-30
A-30 HVAC FDBK RELAY - B
A-31
A-31 FRONT LIGHTS FDBK RELAY - K
A-32
A-32 HYD OIL TEMP (8 VOLT)
A-33
A-33 FOOT THROTTLE
A-34
A-34 HYD OIL FILTER SW1
Printable Version Click Here

HARNESS PART NUMBER WIRING SCHEMATIC

EXLF MFR SCPA 7281095
DLX CAB 7253375 (SCPA MACHINE)
DLX FUEL 7266824
BCT ENG 7242470 T870 (S/N ASWT11602 - ASWT11946)
TAILGATE DOM 7267103
SUSP JSTK 7284703 (S/N B3BZ11130 - B3BZ11141)
BRAKE ADAPTER 7234968
WHL 2 SPD ADP 7159366 Sheet 2 of 18
TRK 2 SPD ADP 7214627
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7281093
579 of 1052
 LEGEND
ENGINE CONTROLLER WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX PARTIAL CONNECTOR
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1-3
CONNECTOR J7
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 4-5
PIN FUNCTION
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 6
1 SW POWER BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 7-8
2 GND BATTERY GROUND 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 9-10 CONNECTOR
3 CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HYDRAULICS PAGE 11
SW POWER
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL CAB DISPLAY PAGE 12
4 GND HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB PAGE 13
5 SW POWER CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
CONTROLS PAGE14
6 GND LIGHTS 6000 THROUGH 6999 PINK PNK (TWO WIRE BREAKS
LIGHTS PAGE 15
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT JOIN ONE WIRE)
9 WATER FUEL SENSOR HVAC PAGE 16
SIGNAL ENGINE 8000 THROUGH 8999 TAN TAN SHEET #
OPTIONS PAGE 17
19 ECU RUN SIGNAL COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
28 MASS AIR FLOW (MAF)
SENSOR FREQUENCY
34 WATER FUEL SENSOR
GROUND
35 MASS AIR FLOW (MAF)
SENSOR TEMP
45 SW POWER SIGNAL
47 ECU CAN 1 LOW
48 ECU CAN 1 HI
56 PREHEATER SIGNAL

Printable Version Click Here

WIRING SCHEMATIC
(SCPA MACHINE)
T870 (S/N ASWT11602 - ASWT11946)
(S/N B3BZ11130 - B3BZ11141)
Sheet 3 of 18
Printed In U.S.A. (PRINTED DECEMBER 2016)
7281093

580 of 1052
 UNSWITCHED BATT POWER
C408 1240 RED/WHT SHEET 12
(BLACK)
C503 RH DLX PANEL
CAB-MFR HARN CONN 1
SP7 1400 RED/WHT
SHEET 13
1450 RED/WHT 6 1450 RED/WHT C667 DOOR HARNESS
FRC1 FUSE RELAY CENTER 1420 RED/WHT
SHEET 12
1110 RED/WHT 2 C500 RH KEY SWITCH
FUSE 11 25 A J1B
1070 RED 1120 RED/WHT 1130 RED/WHT 3 GWY CTRLR 1440 RED/WHT
SHEET 12
SP2
C479 LH PANEL
+12V 1025 RED
FUSE 13 25 A
1160 RED/WHT SP36 1150 RED/WHT 3
J2B
BATTERY MEGAFUSE 1180 RED/WHT 2 AUX CTRLR
100.0 Amps

T4
FUSE 17 25 A
1280 RED 1235 RED/WHT SP58 1260 RED/WHT 48
J5
SHEET 9 1250 RED/WHT 47 DRIVE CTRLR
STARTER
FUSE 4 25 A
1010 RED 1140 RED/WHT
SHEET 16
FRC1 HVAC RELAY
1310 RED

FUSE 1 15 A 1320 RED/WHT

SHEET 15
1350 RED/WHT FRC1 REAR LIGHT RELAY
FUSE 2 20 A SHEET 15
1340 RED FRC1 FRONT LIGHT RELAY
SP26
1330 RED/WHT
SHEET 15
FRC1 FRONT LIGHT RELAY
FUSE 20 5 A
1335 RED 1345 RED/WHT SHEET 5
FRC1 ENGINE ECU RELAY
FUSE 16 25 A
1325 RED SP1 1300 RED 1035 RED/WHT SHEET 5
FRC 1 ENGINE ECU RELAY
1445 RED/WHT
SHEET 9
FRC1 PRE HEATER RELAY
FUSE 18 25 A
1190 RED 1165 RED/WHT SHEET 7 C426 REMOTE RUN, ACD
1095 RED 1100 RED/WHT SHEET 10
HEATER HOSE RELAY
DCU POWER Printable Version Click Here
1220 RED 1230 RED/WHT
SHEET 10

SHEET 9
1460 RED/WHT C412 LH HANDLE HORN
SHEET 17
WIRING SCHEMATIC
1045 RED 10 1105 RED/WHT 10

FUSE 22 25 A
TAILGATE FANS RELAY PWR C408 CAB-MFR CONN
(OPTIONS)
(SCPA MACHINE)
1040 RED 1490 RED/WHT 1410 RED/WHT
SP60 FUSE 24 25 A
SP24
SHEET 17
T870 (S/N ASWT11602 - ASWT11946)
1055 RED 1290 RED 1370 RED/WHT
SHEET 13
C408 CAB-MFR CONN (S/N B3BZ11130 - B3BZ11141)
(ACCESSORIES)
1050 RED
SHEET 5
FRC1 SWITCHED PWR RELAY
Sheet 4 of 18
1030 RED
SHEET 9
FRC1 STARTER RELAY
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7281093
581 of 1052
 FRC1
ENGINE ECU
1525 RNG SHEET 8
SCR INTERCONNECT
SWITCHED POWER J7A ENGINE ECU
+12V RELAY - G
PWR 1506 RNG/WHT 1
SHEET 4 1035 RED/WHT 30 SP73 SP54
87 1540 RNG/WHT 1545 RNG/WHT 1507 RNG/WHT 3

1509 RNG/WHT 1508 RNG/WHT 5

85 86
8005 TAN 45

FRC1 FUSE RELAY CENTER

SHEET 4 1345 RED/WHT
FUSE 21 15 A
1511 RNG/WHT SHEET 9 ENG-CROSSOVER

FUSE 5 25 A C489
1780 RNG/WHT A MFR ACCESSORY
FUSE 6 25 A
1760 RNG/WHT 1850 RNG/WHT
SHEET 13 C408 CAB-MFR CONN (FR WIPER)
1700 RNG/WHT SHEET 12 SW12 DPF SWITCH
1705 RNG/WHT SHEET 12 SW12 DPF SWITCH
FUSE 12 15 A
1790 RNG/WHT 1550 RNG/WHT 1620 RNG/WHT
SHEET 17 C408 CAB-MFR CONN (BKT POSITION) SHEET 12 C479 LH PANEL (BLACK)
1940 RNG/WHT
SHEET 12 T13 LH PANEL BUZZER
1930 RNG/WHT
SHEET 12 C499 RH PANEL PTOL
1775 RNG/WHT
SHEET 12 SW1 BRAKE SWITCH
C428 1960 RNG/WHT
FUSE 14 5 A J2B (LT GRAY) SHEET 12 SW9 TRAVEL CONTROL SWITCH
1805 RNG/WHT 1560 RNG/WHT 22 1785 RNG/WHT
AUX CTRLR CAB-MFR HARN CONN 2 SHEET 14 SW4 H/ISO SWITCH
1950 RNG/WHT
SHEET 12 C500 RH PANEL KEY SWITCH
1660 RNG/WHT 2 1660 RNG/WHT SP42 1590 RNG/WHT
SHEET 12 C503 RH DELUXE PANEL
1765 RNG/WHT SP25 1795 RNG/WHT FUSE 7 25 A
1730 RNG/WHT SP65 1735 RNG/WHT
SHEET 7 C426 REMOTE RUN, ACD
FRC1
1725 RNG/WHT
SWITCHED SHEET 8 C169 ENGINE CAN
POWER RELAY - A FUSE 8 25 A
+12V 1580 RNG/WHT
SHEET 13 C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
PWR 30
SHEET 4 1050 RED FUSE 23 15 A
87 1815 RNG/WHT 1800 RNG/WHT Printable Version Click Here
SHEET 9 ALT EXCITATION
GND 85
SHEET 6
2055 BLK 86
WIRING SCHEMATIC
3450 LBL 21
C428

3380 LBL 4
J1A
GWY CTRLR (LT GRAY)
CAB-MFR HARN CONN 2
(SCPA MACHINE)
1920 RNG/WHT 9 1920 RNG/WHTSP37 1840 RNG/WHT SHEET 7
C449 LH JOYSTICK
T870 (S/N ASWT11602 - ASWT11946)
1830 RNG/WHT
SHEET 7
C450 RH JOYSTICK
(S/N B3BZ11130 - B3BZ11141)
50 J5
1630 RNG/WHT
DRIVE CTRLR Sheet 5 of 18
1740 RNG/WHT SP52
(PRINTED DECEMBER 2016)
1770 RNG/WHT SHEET 14 C537 A22 PUMP HARN (LH SWASH)
1710 RNG/WHT SHEET 14 C536 A22 PUMP HARN (RH SWASH)
7281093
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582 of 1052
 GROUND
2320 BRN
SHEET 11
C112 HYD OIL FILTER SWITCH
2370 BRN J1B
SHEET 13 GWY CTRLR
C408 CAB-MFR CONN (SEATBAR SENSOR)
2220 BRN SP12 2230 BRN 17
SHEET 11
C108 HYD TEMP SENDER
2190 BRN
2 SHEET 11
2001 BLK C105 HYD CHG PRESSURE SENDER
4 2002 BLK SP53 2820 BLK SP75 2805 BLK 2180 BRN
J7A SHEET 9
ENG ECU CTRLR 6 2003 BLK C355 FUEL HARN (FUEL SENDER)
2150 BRN
SP50 2235 BLK SHEET 9
27 2040 BLK C405 AIR FILTER SWITCH
T32 2004 BLK J5
ECU CASE GND DRIVE CTRLR 28 2490 BLK 2690 BRN
SHEET 9
2880 BLK C408 CAB-MFR CONN (HAND THRTL)
SHEET 10
C120 SCR-MFR CONN
2430 BRN 18
2080 BLK SHEET 9
SHEET 7 ENGINE TEMP GND
C449 LH JOYSTICK T6
2070 BLK BATT GND
SHEET 7 C408
C450 RH JOYSTICK (BLACK)
2920 BLK CAB-MFR HARN CONN 1
SHEET 12 2765 BLK
C479 LH PANEL (BLACK) SHEET 15
2940 BLK SP4 2950 BLK 10 2950 BLK C408 CAB-MFR CONN (FR LIGHTS)
SHEET 12
C499 PTOL 2745 BLK
SHEET 16
2960 BLK 16 SP3 C408 CAB-MFR CONN (HVAC)
SHEET 12 2510 BLK 2110 BLK
C500 RH PANEL KEY SWITCH J1B 2790 BLK T8
GWY CTRLR 15 2500 BLK SHEET 13 BATT GND
2250 BLK C408 CAB-MFR CONN (ACCESSORIES)
SHEET 12
C503 RH DELUXE PANEL 2780 BLK
2065 BLK C428 SHEET 17
SHEET 12 16 C408 CAB-MFR CONN (OPTIONS)
(LT GRAY) 2540 BLK
SW12 DPF SWITCH 2730 BLK
2930 BLK CAB-MFR HARN CONN 2 J2B 15 SHEET 13
SHEET 12 2550 BLK SP282090 BLK
AUX CTRLR C408 CAB-MFR CONN (ACCESSORIES, OPTIONS)
SW1 BRAKE SWITCH SP47
2830 BLK 2900 BLK 1 2900 BLK
SHEET 17
SW6 BKT POSITION SWITCH
2700 BLK 2770 BLK
SHEET 12 SHEET 17
SW9 TRAVEL CONTROL SWITCH C355 FUEL HARN (PWR BOB/AC)
2785 BLK 2200 BLK
SHEET 17 SHEET 11
C126 HORN C425 BRAKE
2620 BLK
SHEET 15 C103 C489
T16 RH REAR LIGHT B 2720 BLK
TAILGATE HARN MFR ACCESSORY
SHEET 14 2650 BLK
SP51 2600 BLK B SP6 2390 BLK 10 T1 T10
T20 BU ALARM 2600 BLK 2015 BLK
2640 BLK BATT GND SHEET 9 ENGINE
SHEET 15 2400 BLK 14 ALTERNATOR GROUND GROUND
C602 LH REAR LIGHT SHEET 9
LEFT TAILGATE FANS GND
2610 BLK 2405 BLK 14
SHEET 15 SHEET 9
C603 RH REAR LIGHT RIGHT TAILGATE FANS GND
2630 BLK 2455 BLK
SHEET 15 SHEET 17 2300 BLK
T18 LH REAR LIGHT C423 BKT POSITION SOLENOID SP27
2710 BLK Printable Version Click Here
SHEET 7
C426 REMOTE RUN, ACD
SHEET 8
C169 ENGINE CAN
2715 BLK
WIRING SCHEMATIC
2290 BLK
SHEET 15
FRC1 REAR LIGHT RELAY
2045 BLK SHEET 16
D4 COMPRESSOR DIODE (SCPA MACHINE)
2295 BLK 18
2115 BLK SP55
SHEET 9
TAILGATE FANS RELAY GND
2105 BLK
T870 (S/N ASWT11602 - ASWT11946)
SHEET 15
FRC1 FRONT LIGHT RELAY
SHEET 5
2055 BLK (S/N B3BZ11130 - B3BZ11141)
FRC1 SWITCHED POWER RELAY
SHEET 16 2030 BLK Sheet 6 of 18
FRC1 HVAC RELAY
2005 BLK
SHEET 9 (PRINTED DECEMBER 2016)
FRC1 STARTER RELAY
SHEET 15
2120 BLK 7281093
FRC1 FRONT LIGHT RELAY
Printed In U.S.A.
583 of 1052
 CAN BUS
C408
J1B (BLACK)
GWY CTRLR CAB-MFR HARN CONN 1

8 9260 PUR 9230 PUR SP31 9250 PUR SP19 9220 PUR 4 9220 PUR SP18 9410 PUR SP39 9430 PUR SP35 9450 PUR 9460 PUR 4
CAN LO C479
9 9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT SP20 9120 PUR/WHT 3 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT 3 LEFT PANEL (BLACK)
CAN HI
RE016 SP30 SP17 SP38 SP34 RE019
120 OHM 120 OHM
0.5 W 0.5 W
RESISTOR RESISTOR
J5 9440 PUR 4
DRIVE CTRLR C503
9340 PUR/WHT 2 RIGHT DELUXE PANEL
9290 PUR 22
9190 PUR/WHT 12
1830 RNG/WHT 1
SHEET 5 C450
2070 BLK 2
SHEET 6 RIGHT JOYSTICK
9320 PUR/WHT 3 SHEET 14
9420 PUR 4

1840 RNG/WHT 1
SHEET 5 C449
2080 BLK 2
SHEET 6 LEFT JOYSTICK
J2B 9300 PUR/WHT 3
AUX CTRLR SHEET 14
9400 PUR 4
9280 PUR 8
9180 PUR/WHT 9
J2B C426
AUX CTRLR Remote Run Tool, ACD

14 9500 PUR/WHT A
CAN HI
20 9600 PUR B Printable Version Click Here
CAN LO

WIRING SCHEMATIC
J1B
GWY CTRLR
(SCPA MACHINE)
21 3090 LBL D
REMOTE RUN KEY
T870 (S/N ASWT11602 - ASWT11946)
C
SHEET 5
1735 RNG/WHT E
SWITCHED POWER
(S/N B3BZ11130 - B3BZ11141)
1165 RED/WHT F
SHEET 4
SHEET 6
2710 BLK G UNSWITCHED POWER
GROUND
Sheet 7 of 18
Printed In U.S.A. (PRINTED DECEMBER 2016)
7281093

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 J7A
ECU CNTRLR

47
ENGINE CAN BUS
9200 PUR 9215 PUR
SP81
9415 PUR
SP90
9210 PUR SP67 9265 PUR SP71 9275 PUR SP70
C121
DOSING CONTROL UNIT

65
CAN LO 9245 PUR 120 Ohm Terminator
48 9100 PUR/WHT 9115 PUR/WHT 9315 PUR/WHT 9110 PUR/WHT SP68 9165 PUR/WHT SP72 9175 PUR/WHT SP69 9145 PUR/WHT 66 Resistor internal to Controller
CAN HI
RE014 SP82 SP91
120 OHM
0.5 W
RESISTOR
J1B
GWY CTRLR C163
NOx PRETREATMENT
9205 PUR 20
9105 PUR/WHT 14 9295 PUR 3
9195 PUR/WHT 4
2835 BLK 2
2875 BLK 5
1

SHEET 10 2870 BLK

NOx GROUND SP78 C164
NOx POST TREATMENT

2815 BLK 2
9285 PUR 3
9185 PUR/WHT 4
5
1635 RNG/WHT 1

1525 RNG 1645 RNG/WHT

SHEET 5
SP76
SCR INTERCONNECT
C161
DEF TANK
1640 RNG/WHT 4
C169
9225 PUR 1
ENGINE CAN
9125 PUR/WHT 2
1 1725 RNG/WHT 2825 BLK 3
SHEET 5 SHEET 10
2 2715 BLK SHEET 6
3 C121
9155 PUR/WHT
DOSING CONTROL UNIT
4 9255 PUR
5 9720 PUR/WHT 82
WIRING SCHEMATIC
6 9820 PUR 60 Printable Version Click Here
(SCPA MACHINE)
T870 (S/N ASWT11602 - ASWT11946)
(S/N B3BZ11130 - B3BZ11141)
Sheet 8 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A.
7281093

585 of 1052
 SHEET 4
1030 RED
PWR 30
87
FRC1
+12V STARTER RELAY - M

8200 TAN
C111
MFR-BCT HARN CONN

A 8220 TAN
STARTER
S B
ENGINE SHEET 4
M
3560 LBL B 3560 LBL R
GND 85 86 8210 TAN C 1015 RED
SHEET 6 2005 BLK SHEET 5 1800 RNG/WHT
FUSE 12
7 8210 TAN B
22 ALTERNATOR G
3560 LBL 1800 RNG/WHT
C405 EXCITATION
2150 BRN B GND 2015 BLK
SHEET 6 AIR FILTER SHEET 6
16 3150 LBL A SIG
SWITCH (NC) ENGINE GROUND TERMINAL
J1A
GWY CTRLR FRC1
TAILGATE FANS
FUSE 15 A
25 3105 LBL 18 RELAY - C
12 3100 LBL 18 C119
C104 LEFT TAILGATE
87 A B C171
TAILGATE FANS CONN FAN CONN
TAILGATE FANS RELAY PWR 1105 RED/WHT 10 87A 8110 TAN 14 1 8110 TAN 14 8125 TAN 14 A
30 LEFT
SHEET 4 TAILGATE 2400 BLK 14 2 2400 BLK 14 B
2295 BLK 18 85 86 FANS GND SHEET 6 8105 TAN 14 3 8105 TAN 14 FUSE 15 A
TAILGATE FANS RELAY GND
RIGHT 2405 BLK 14 4 2405 BLK 14 C113
9 8100 TAN 18 SHEET 6
TAILGATE SHEET 6 C172 RIGHT TAILGATE
J1B A B FAN CONN
C355 FANS GND
GWY CTRLR A
FUEL HARN 8135 TAN 14
C406
B
12 3180 LBL C 3180 LBL A SIG
FUEL SENDER
2180 BRN D 2180 BRN B GND
SHEET 6 (30 - 270 OHM)
10 3690 LBL
C428
C120 (LT GRAY)
SHEET 6 ENGINE C114 INTAKE HEATER
2430 BRN 18 2 CAB-MFR HARN CONN 2 +12V CONTACTOR
TEMP HAND THROTTLE
18 1 T29 PWR FUSE 150 A
3110 LBL 18 SENSOR SHEET 13 5690 YEL 7 5690 YEL C +5V PWR 30
(950-4400 OHM) 1060 RED 1 2 1065 RED/WHT 87 8515 TAN SP77 8500 TAN
6 T14
3690 LBL 3690 LBL A
SIG T26 T27 8510 TAN 85 86 1445 RED/WHT
2690 BRN 8 2690 BRN B GND
4 8007 TAN SHEET 4
SHEET 6 D 8505 TAN T31
E
J7A F
ENG ECU CTRLR
8020 TAN SP74
SHEET 10
19 8008 TAN
C100 Printable Version Click Here
9 3865 LBL 1 WATER IN FUEL SENSOR
SIG
34 2865 BRN 2 GND (FUEL FILTER) WIRING SCHEMATIC
56

C118
(SCPA MACHINE)
28 8013 TAN

35 8014 TAN 1511 RNG/WHT

ENG-CROSSOVER
1
T870 (S/N ASWT11602 - ASWT11946)
ENG-CROSSOVER SHEET 5
8013 TAN
8014 TAN
2
3
FREQ
(S/N B3BZ11130 - B3BZ11141)
TEMP

T42
3420 LBL 4
Sheet 9 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7281093

586 of 1052
 DOSING CONTROL UNIT HOSE HEATER MAIN
1100 RED/WHT 30
87 8090 TAN
SHEET 4 T33
2975 BLK 85 86
DCU CASE GND

2915 BLK
C121
DOSING CONTROL UNIT

1230 RED/WHT SP62 1245 RED/WHT 5 93 8310 TAN

SHEET 4 1265 RED/WHT 6
C123
1255 RED/WHT 73 67 HOSE 1 HEATER

2310 BRN
1275 RED/WHT 51 68 7998 WHT SP87 8120 TAN 1
2
89 8320 TAN
2880 BLK SP63 2925 BLK 1
SHEET 6 90 7999 WHT
C120 SCR-MFR CONN SHEET 8 2825 BLK 2935 BLK 2 HOSE 1 HEATER
2945 BLK 7 72 SP88 8330 TAN 30
8340 TAN

8140 TAN
87 2955 BLK SP86
Nox Ground 2870 BLK 2855 BLK 29
SHEET 8 C124
2145 BRN 85 86 HOSE 2 HEATER
8020 TAN 22
94 1
SHEET 9 8550 TAN
8240 TAN 2
53 2135 BRN SP85
C155
1 2170 BRN 75 HOSE 2 HEATER
TANK HEATING VALVE

8150 TAN
4 8540 TAN 92 49 SP89 30
8260 TAN 8250 TAN
87 2965 BLK
C156 C125

2985 BLK
2140 BRN 85 86 HOSE 3 HEATER
REDUCTION AGENT 1 8850 WHT 80
50 8560 TAN 1
METERING VALVE 2 8950 BLK 58
2165 BLK 2
59 8350 TAN
C157
1 8900 TAN 83 HOSE 3 HEATER
CATALYST TEMPERATURE
2 61 27 8370 TAN SP61
SCR INLET 2025 BRN 8360 TAN 30
87
C158
1 8520 TAN 62 85 86
2125 BRN
CATALYST TEMPERATURE
SCR OUTLET 2 2160 BRN 84 28 8600 TAN
C159
1 8800 TAN 31 C122
ENVIRONMENTAL TEMPERATURE SUPPLY MODULE
2 2050 BRN 9
4 1690 RNG/WHT 11 Printable Version Click Here
HEATER BATT+
C160 3 12

CATALYST TEMPERATURE
1 8530 TAN 18 TXL 34
55
8650 TAN
3
HEATER SIGNAL
WIRING SCHEMATIC
1695 RNG/WHT PUMP MOTOR BATT +
DOC INLET 2 2075 BRN 18 TXL 12
76 8700 TAN
2
PUMP MOTOR CONTROL SIGNAL (SCPA MACHINE)
54 2095 BRN 4

77 1680 RNG/WHT
5
PUMP MOTOR GND
T870 (S/N ASWT11602 - ASWT11946)
PURGING PUMP BATT +
78 8750 TAN 6
PURGING PUMP SIGNAL (S/N B3BZ11130 - B3BZ11141)
17 10

39
1685 RNG/WHT
3000 LBL
9
PRESSURE SENSOR BATT+
Sheet 10 of 18
PRESSURE SENSOR SIGNAL
40 2085 BRN 8
PRESSURE SENSOR GND (PRINTED DECEMBER 2016)
Printed In U.S.A. 7281093
587 of 1052
 HYDRAULICS SHEET 6
4200 LGN
2200 BLK
C425

B
A
C
4200 LGN
2200 BLK
C308
A
B
BRAKE
SOLENOID
9.8 OHM
12 V
TRACK 2 SPEED
ADAPTER (SEE
ADDITIONAL
OPTIONS DWG)
WHEEL 2 SPD ADP HARNESS 7159366
TRACK 2 SPD ADP HARNESS 7214627
TRACK SINGLE SPD BRAKE ADP HARNESS 7234968

C108
2220 BRN B HYDRAULIC
GND
SHEET 6 TEMPERATURE
32 3220 LBL A SIG SENDER
500 - 3000 OHM
C112 (8 VOLT)
J1A 34 3320 LBL A SIG HYDRAULIC OIL
GWY CTRLR 2320 BRN B GND FILTER SWITCH (NC)
SHEET 6

C446
18 2910 BRN 2 GND HYDRAULIC
4010 LGN 1 SIG FAN SOLENOID
7.2 OHM 12 V
C420
1 2410 BRN B GND HYDRAULIC LOCK
4410 LGN A SIG SOLENOID
9.8 OHM 12 V
C105
2190 BRN B GND HYDRAULIC
SHEET 6
3190 LBL C SIG CHARGE
5190 YEL A +8V PWR PRESSURE
0.5-7.5V
4200 LGN

19 13 1 23 6
J1B Printable Version Click Here
GWY CTRLR

WIRING SCHEMATIC
C418
J2A
AUX CTRLR
18 2330 BRN 2
1
GND
SIG
FRONT ROD
SOLENOID (MALE)
(SCPA MACHINE)
4330 LGN
3.3 OHM PWM
C419
T870 (S/N ASWT11602 - ASWT11946)
1 2 GND
2340 BRN
4340 LGN 1 SIG
FRONT BASE
SOLENOID (FEMALE) (S/N B3BZ11130 - B3BZ11141)
3.3 OHM PWM
Sheet 11 of 18
19 13 (PRINTED DECEMBER 2016)
J2B
Printed In U.S.A. AUX CTRLR
7281093

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SHEET 5
1940 RNG/WHT
T13
BUZZER (+)

LEFT PANEL
CAB DISPLAY C499
Press To Operate Loader
7040 WHT BUZZER
C479 (PTOL)
T2
LEFT PANEL (BLACK) 1930 RNG/WHT 1
BUZZER (-) SHEET 5 SWITCHED POWER
10 C408 2940 BLK 3
7040 WHT BUZZER SHEET 6 GROUND
(BLACK)
2920 BLK 2 CAB-MFR HARN CONN 1
SHEET 6 GROUND
1960 RNG/WHT 1440 RED/WHT 1
SHEET 5 SHEET 4 UNSWITCHED POWER 20 3030 LBL 1 3030 LBL 2
PTOL OUTPUT
SW9 1620 RNG/WHT 5 SWITCHED POWER
SHEET 5 19 2380 BRN 12 2380 BRN 4
TRAVEL CONTROL PTOL LED
SWITCH (OPTIONAL) 3400 LBL 11 LEFT BLINKER INPUT J1A
SHEET 17
GWY CTRLR
5 6 SHEET 17
3500 LBL 8 C500
RIGHT BLINKER INPUT RIGHT PANEL - KEY SWITCH
4
2700 BLK 2 3 3650 LBL 7 24 2 8130 TAN 2
SHEET 6 TRAVEL CONTROL INPUT 8130 TAN START
1 9
3600 LBL
PARK BRAKE INPUT
SW1 6 6
3 2 BRAKE SWITCH 12
1
3610 LBL 4 5
SHEET 5 1775 RNG/WHT 6
2930 BLK C480 J1B 22 3040 LBL 14 4
SHEET 6 LEFT PANEL (GRAY) 3040 LBL RUN/ENTER SWITCH
GWY CTRLR
SHEET 13 3620 LBL 12
DOOR SIGNAL
11 1950 RNG/WHT 5
SHEET 5 SWITCHED POWER
10 1420 RED/WHT 1
SHEET 4 UNSWITCHED POWER
3 2960 BLK 3
SHEET 6 GROUND
3610 LBL 2
PARK BRAKE OUTPUT
SW12
8
DESOX INHIBIT SWITCH 7 C503
(OPT KIT) 6 RIGHT PANEL DELUXE DISPLAY
1700 RNG/WHT 7 9 8050 TAN 4 1590 RNG/WHT 5
SHEET 5 SHEET 5 SWITCHED POWER
1705 RNG/WHT 10 8 8055 TAN 5
SHEET 5 DESOX INHIBIT LAMP 1240 RED/WHT 1
SHEET 4 UNSWITCHED POWER
2065 BLK 2 4 8070 TAN 9
SHEET 6 DESOX INHIBIT 2250 BLK 3
1 SHEET 6 GROUND
1 6
3 8060 TAN

Printable Version Click Here

WIRING SCHEMATIC
(SCPA MACHINE)
T870 (S/N ASWT11602 - ASWT11946)
(S/N B3BZ11130 - B3BZ11141)
Sheet 12 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A.
7281093

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 CAB
C438 * DLX CAB HARN 7253375 ONLY
(DK GRAY)
CAB-MFR HARN CONN 3 (NOT IN STD CAB HARN)
1850 RNG/WHT 2 1850 RNG/WHT
* C212
POWER
SHEET 5 SOCKET
2795 BLK 1 GND
1375 RED/WHT 2 +12V PWR
C408
(BLACK)
CAB-MFR HARN CONN 1
1370 RED/WHT 7 1370 RED/WHT SP45
*
1390 RED/WHT
T37
DOME LIGHT (+)
SHEET 4
DOME
SP41 2010 BLK LIGHT
C129
CAB ACCESSORY
1210 RED/WHT A +12V BATT PWR * T38
DOME LIGHT (-)
1580 RNG/WHT 5 1580 RNG/WHT SP8 1865 RNG/WHT B +12V SW PWR
SHEET 5
2800 BLK C GND
1510 RNG/WHT
SHEET 17
1885 RNG/WHT SHEET 17
SP44
2210 BLK SHEET 17
2730 BLK 11 2730 BLK
SHEET 6 2885 BLK SHEET 17
2060 BLK SHEET 14
C428
(LT GRAY) * C667
DOOR HARNESS
CAB-MFR HARN CONN 2 (SEE ADDITIONAL
OPTIONS DWG)
2790 BLK 14 2790 BLK
SHEET 6
1850 RNG/WHT 1
WIPER SWITCH, MOTOR SWITCHED POWER
3620 LBL 4
SHEET 12 DOOR SIGNAL
1400 RED/WHT 5
SHEET 4 DOOR UNSW PWR
6
C482 SEATBAR 2840 BLK 2
WIPER MOTOR GROUND
J1B
GWY CTRLR SHEET 6
2370 BRN 4 2370 BRN A GND SENSOR 7310 WHT 3
WASHER SIGNAL

11 3370 LBL 5 3370 LBL B SIG

24 5100 YEL SP13 5370 YEL 3 5370 YEL C +5V PWR

+5V Printable Version Click Here
HARNESS WASHER PUMP
SHEET 9 5690 YEL 7253378
WIRING SCHEMATIC
(SCPA MACHINE)
* C252 C253
PWR
A 7310 WHT 1 WASHER
MOTOR
T870 (S/N ASWT11602 - ASWT11946)
2845 BLK B 2845 BLK 2 GND (S/N B3BZ11130 - B3BZ11141)
Sheet 13 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7281093
590 of 1052
 SW4 J5
DRIVE CTRLR

CONTROLS
HAND/FOOT
(ACS)
H/ISO 33
(SJC, AWS) 34
SWITCH
SHEET 5
1785 RNG/WHT 2 1
3 40 SP11
+5V 5890 YEL
2060 BLK 5 6
SHEET 13
4
C438 23
J5 (DK GRAY) 24
DRIVE CTRLR CAB-MFR HARN CONN 3

6 4235 LGN 7 4235 LGN C536

5810 YEL 2 C543 A22 PUMP HARNESS
16 4275 LGN 8 4275 LGN
29 SP56 2810 BRN 4 2810 BRN 1
4 9 2890 BRN GND
4550 LGN 4550 LGN RIGHT
8 3810 LBL 3 3810 LBL 3 SIG SWASHPLATE
1710 RNG/WHT 1 1710 RNG/WHT 2 +12V PWR
SHEET 5
C103 C537
TAILGATE HARN 5860 YEL 2 C542
T19 TERMINAL (+)
36 7100 WHT C 7100 WHT 2860 BRN 4 2860 BRN 1 GND LEFT
BACK UP 7 3860 LBL 3 3860 LBL 3 SIG SWASHPLATE
2650 BLK ALARM 1770 RNG/WHT 1 1770 RNG/WHT 2 +12V PWR
SHEET 6 SHEET 5
T20 TERMINAL (-) C501 C546
43 4260 LGN 1 4260 LGN 1
RIGHT FORWARD DRIVE
42 2660 BRN 2 2660 BRN 2
C460
1 1830 RNG/WHT 1 +12V PWR
C547
C450 2 2070 BLK 2 GND 44 3 4250 LGN 1
RIGHT JOYSTICK
RIGHT 4250 LGN
RIGHT REVERSE DRIVE
3 9560 PUR/WHT 3 CAN HI HANDLE 45 2650 BRN 4 2650 BRN 2
4 9660 PUR 4 CAN LO
C545
31 4280 LGN 5 4280 LGN 1
C459 41 2680 BRN 6 2680 BRN 2 LEFT REVERSE DRIVE
1 1840 RNG/WHT 1 +12V PWR

C449 2 2080 BLK 2 GND C544

LEFT JOYSTICK 3 9540 PUR/WHT 3 CAN HI
LEFT 21 4270 LGN 7 4270 LGN 1
11 8 2670 BRN 2 LEFT FORWARD DRIVE
HANDLE 2670 BRN
4 9640 PUR 4 CAN LO

SUSP SEAT JOYSTICK HARNESS 7163706 C474

26 4210 LGN A BRAKE CONN
USED WITH ROADLIGHT KIT

C421 Printable Version Click Here

J1A 10 2980 BRN 3 GND
GWY CTRLR 4980 LGN 1 SIG TILT SPOOL LOCK
7.8 OHM 12V
WIRING SCHEMATIC
2

C422
(SCPA MACHINE)
2 2990 BRN 3
4990 LGN 1
GND
SIG
LIFT SPOOL LOCK
7.8 OHM 12V
T870 (S/N ASWT11602 - ASWT11946)
2
(S/N B3BZ11130 - B3BZ11141)
7 5
Sheet 14 of 18
J1B
GWY CTRLR (PRINTED DECEMBER 2016)
7281093
Printed In U.S.A.
591 of 1052
 C434-1

LIGHTS
2735 BLK B GND LEFT FRONT
C408
6100 PNK A SIG WORK LIGHT
(BLACK)
CAB-MFR HARN CONN 1 37.00 Watts
C434-2
2765 BLK 9 2765 BLK SP14 2750 BLK B GND
SHEET 6 LEFT FRONT
6110 PNK A SIG WORK LIGHT
50.00 Watts

C435-1
8 6000 PNK SP15 6120 PNK A SIG RIGHT FRONT
RC1 WORK LIGHT
2760 BLK B GND
FRONT WORK 37.00 Watts
LIGHTS RELAY - 1
C438 C435-2
(DK GRAY) 6130 PNK A SIG
SHEET 4 1350 RED/WHT 30 CAB-MFR HARN CONN 3 RIGHT FRONT
87 6620 PNK SP23 6610 PNK 2705 BLK B GND WORK LIGHT
50.00 Watts
13 6610 PNK SP64
SHEET 6 2120 BLK 85 86

6630 PNK

6000 PNK
RC2
FRONT WORK
LIGHTS RELAY - 2 C103
+12V TAILGATE HARN C603
PWR 2610 BLK 2 GND
1330 RED/WHT 30 SHEET 6 RIGHT REAR
SHEET 4 87 6340 PNK SP10 6310 PNK A 6310 PNK SP49 6320 PNK 1 SIG
TAIL LIGHT
GND 85 86
2115 BLK C602
SHEET 6
6330 PNK 1 SIG
2640 BLK LEFT REAR
2 GND
SHEET 6 TAIL LIGHT
5 6320 PNK
31 3460 LBL
J1A
17 6210 PNK
GWY CTRLR
28 3440 LBL Printable Version Click Here

2620 BLK
T16 TERMINAL (-) WIRING SCHEMATIC
GND RIGHT REAR
SHEET 6

FRC1
6210 PNK SIG WORK LIGHT
(SCPA MACHINE)
REAR LIGHT T15 TERMINAL (+)
+12V RELAY - E
PWR 30
T870 (S/N ASWT11602 - ASWT11946)
1320 RED/WHT T17 TERMINAL (+)
6200 PNK H SP96
SHEET 4 87 6200 PNK 6220 PNK
2630 BLK
SIG
GND
LEFT REAR
WORK LIGHT
(S/N B3BZ11130 - B3BZ11141)
GND 85 86 SHEET 6
2045 BLK
SHEET 6 T18 TERMINAL (-) Sheet 15 of 18
(PRINTED DECEMBER 2016)
7281093
Printed In U.S.A.

592 of 1052
 2440 BLK * C610
2 GND

HVAC
HVAC DUCT
7440 WHT 1 SIG FAN

2560 BLK * C483

C BLK
7420 WHT A DBL POTENTIOMETER
(TEMP CONTROL
* DLX CAB HARN 7253375 ONLY 7425 WHT B WHT SWITCH)

(NOT IN STD CAB HARN) * C635

D SIG
2130 BLK C GND HEATER
SP48 7430 WHT A +12V PWR VALVE
B
E
F

FRC1
HVAC RELAY - B
C438
(DK GRAY)
*BLOWER
SW10

+12V CAB-MFR HARN CONN 3 SWITCH

PWR 30 OFF
1140 RED/WHT
SHEET 4 87 1500 RNG/WHT 10 1500 RNG/WHT 5 2
1
2030 BLK GND 85 86 4
SHEET 6 7410 WHT 6
3 7530 WHT * C611
1 14.00 Amps High
3 7520 WHT 2 7.50 Amps Med BLOWER
7050 WHT MOTOR
SW11 7510 WHT 3 5.00 Amps Low
J1A
30 3050 LBL
SHEET 6
2745 BLK 11 2745 BLK SP16 *
AC SWITCH 2580 BLK 4
GWY CTRLR
2100 BLK 3
C 7400 WHT
7015 WHT 1
11 7021 WHT SP40 7020 WHT 12
C630
* 3
THERMOSTAT

AC EVAPORATOR C350 2570 BLK 2 Printable Version Click Here

SWITCH B 7023 WHT 7020 WHT 1
A 7024 WHT WIRING SCHEMATIC
7025 WHT
C486
1 SIG
(SCPA MACHINE)
MAGNET CLUTCH
2290 BLK 2280 BLK
2 GND
(COMPRESSOR) T870 (S/N ASWT11602 - ASWT11946)
SHEET 6
D4
(S/N B3BZ11130 - B3BZ11141)
Sheet 16 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7281093

593 of 1052
 C355
C428
(LT GRAY)
#
OPTIONS
# C607
FUEL HARN CAB-MFR HARN CONN 2
DLX FUEL HARN 7266824 ONLY
SIG 1 4470 LGN E 4470 LGN 11 4470 LGN
POWER BOB
CLOSE GND 2 2470 BLK 2770 BLK B 2770 BLK
SHEET 6 4480 LGN
(NOT IN STD FUEL HARN)
SW5
*POWER 2 1
# C606 BOBTACH
SWITCH 5
3
4
* DLX CAB HARN 7253375 ONLY
GND 2 2480 BLK 6
POWER BOB
OPEN
SIG 1 4480 LGN F 4480 LGN 10 (NOT IN STD CAB HARN)
6010 PNK 13 6010 PNK

1380 RED/WHT
1550 RNG/WHT 12 1550 RNG/WHT
SHEET 5

C438
(DK GRAY)
CAB-MFR HARN CONN 3 1200 RED/WHT

C411
B
SHEET 4
1410 RED/WHT 1 1410 RED/WHT 1430 RED/WHT X
L
* FLASHER
T3

LEFT HANDLE CONN

C SHEET 12 3500 LBL
(FLASHER) 5 WAY D1
A 6515 PNK 6500 PNK 6 6500 PNK 6530 PNK
*BEACON
SW2

6570 PNK
(SEE ADDITIONAL E
OPTIONS DWG) D 6415 PNK 6400 PNK 3 6400 PNK
D2 6430 PNK SWITCH
3400 LBL 2725 BLK 6
C103 SHEET 12 *HAZARD
SW3
2
1
6700 PNK
4
1
5
2
TAILGATE HARN 3
SWITCH 4 3
5
EURO TAIL LIGHTS E 6410 PNK (PINS 3 & 6 2850 BLK
INTERNALLY 6
D
(SEE ADDITIONAL
OPTIONS DWG)
6510 PNK
INSULATED) * C670E
2780 BLK 4 2780 BLK 2780 BLK 2420 BLK D
C423 SHEET 6 BEACON/FLASHER
3 6440 PNK F EXTERIOR HARNESS
BUCKET SIG A 4450 LGN D3 4455 LGN 5 4455 LGN 1
4
2 * SW6
BUCKET 6540 PNK B (SEE ADDITIONAL
OPTIONS DWG)
POSITION 2830 BLK 5 POSITION C
SOLENOID GND B 2450 BLK 2455 BLK SHEET 6 SWITCH A
SHEET 6 6
9.8 OHM
C408
(BLACK) * C676

LEFT HANDLE C412

CAB-MFR HARN CONN 1 SHEET 6
2785 BLK
C126
B GND LEFT
*+ C279
1 7820 WHT
RADIO CONN
3
C277
(HORN) 2 WAY
(SEE ADDITIONAL
B
A 1460 RED/WHT
7210 WHT 13 7210 WHT A SIG HORN SPEAKER
-
2 7830 WHT 4
* 1
OPTIONS DWG) SHEET 4 2
C497
SJC
RIGHT
*- C278
2 7810 WHT 6 3
AIR RIDE
SEAT
5 7200 WHT C SPEAKER 1 7800 WHT 5 1510 RNG/WHT 4 PWR
HORN/BLINKER SHEET 13
4 6420 PNK A + 1 2210 BLK 5 GND
(SEE ADDITIONAL SHEET 13 1885 RNG/WHT SHEET 13
3 6520 PNK B OPTIONS DWG) 2 6
J2A
SHEET 13 2885 BLK
AUX CTRLR
C415
B HIGH FLOW
26 2460 BRN
4460 LGN A
GND
SIG SOLENOID
7.5 OHM 12 V
WIRING SCHEMATIC
J2B
AUX CTRLR
26 (SCPA MACHINE) Printable Version Click Here
C441
TRACK 2 SPEED
T870 (S/N ASWT11602 - ASWT11946)
J1A 26 2350 BRN 2 GND TWO SPEED
GWY CTRLR 4350 LGN 1 SIG SOLENOID
5.1 OHM 12 V
ADAPTER
(SEE ADDITIONAL (S/N B3BZ11130 - B3BZ11141)
OPTIONS DWG)
J1B
GWY CTRLR
26
Sheet 17 of 18
(PRINTED DECEMBER 2016)
Printed In U.S.A. 7281093
594 of 1052
 T14
PRE HEATER

WASTE GATE
C153
1
2
PRE HEATER 179

186
J7B
ENG ECU CTRLR
(DOOSAN HARNESS)
105
122
TEMP SENSOR 1
SENSOR RETURN 1
C130

C131
EXHAUST GAS
TEMP SENSOR
BEFORE DPF
ENGINE
SUPPLIED
C152 106 TEMP SENSOR 2 EXHAUST GAS
1 POSITION SENSOR 161 123 TEMP SENSOR
SENSOR RETURN 2
WASTE GATE BEFORE TURBINE
2 POSITION FEEDBACK 113
POSITION C132
3 POSITION GND 121 107 TEMP SENSOR 3 EXHAUST GAS
124 TEMP SENSOR
C151 SENSOR RETURN 3
BEFORE DOC
1 EGR VREF3 164
C133
5 POSITION SIGNAL 116 194 TEMP SENSOR 4 EXHAUST GAS
EGR VALVE
3 172 169 TEMP SENSOR
DC MOTOR POSITION RETURN SENSOR RETURN 4
AFTER DPF
6 H BRIDGE POS 192
C134
2 H BRIDGE NEG 193 166 VREF2 EG DPS 1
C150 108 PRESSURE SENSOR 3 EXHAUST GAS
AIR SENSOR 114 144 2 PRESSURE SENSOR
AMBIENT AIR
SENSOR RETURN
TEMP SENSOR
AIR RETURN 171
C135
C149 184 5
H BRIDGE POS
1 COOLANT TEMP SENSOR 109
COOLANT TEMP 183 H BRIDGE NEG 4 INTAKE
SENSOR 2 COOLANT RETURN 145 THROTTLE
163 VREF 3 THROTTLE POSITION 1
C148 170 POSITION SENSOR GND 3
1 FUEL TEMP SENSOR 110 115 2
FUEL TEMP POSITION FEEDBACK ANALOG
SENSOR 2 FUEL RETURN 146 185 GLOW PLUG RELAY DRIVER C136
C147 165 VREF3 OIL PRESSURE
1 131 OIL PRESSURE &
ENGINE BLOCK SENSOR SIGNAL 111 OIL PRESSURE SENSOR TEMPERATURE
ACCELEROMETER 1 2 SENSOR RETURN 130 148 SENSOR
RETURN GND
SHIELD 128
104 OIL TEMPERATURE SENSOR
C146
132 C137
1 SENSOR SIGNAL
ENGINE BLOCK 156 UN 6
ACCELEROMETER 2 2 SENSOR RETURN 133 O2 SENSOR
SHIELD 129 157 VM 2 & HEATER
154 IA 5
C145 155 1
160 IP
CRANK SENSOR POS SHEET ?
VR CRANK 182 O2 HEATER 3
SENSOR CRANK SENSOR NEG 136
4
C144
C138
1 SENSOR RETURN 147 Printable Version Click Here
141 VREF2 INTAKE PRESS B
CAM SHAFT
SENSOR
2
3
POS SENSOR
VREF1 CAM
159
140
112 INTAKE PRESS SENSOR A
INLET TEMP WIRING SCHEMATIC
167 INTAKE PRESS RETURN D PRESSURE
C143 134 INTAKE AIR TEMP SENSOR C SENSOR
(SCPA MACHINE)
1 RAIL PRESSURE SENSOR 135 168 ?
INTAKE AIR TEMP RETURN
RAIL PRESSURE
SENSOR
2 SENSOR RETURN 119 T870 (S/N ASWT11602 - ASWT11946)
3 138 C139
VREF 1 SENSOR

C141
127
126
FUEL INJECTOR HSDA
FUEL INJECTOR LSD1A CYL 1
(S/N B3BZ11130 - B3BZ11141)
FUEL INJECTOR HSDB 151
CYL 3
FUEL INJECTOR LSD1B 175
150
C140 Sheet 18 of 18
FUEL INJECTOR HSDB
C142 174 CYL 2
FUEL INJECTOR LSD2B
FUEL INJECTOR HSDA 103 (PRINTED DECEMBER 2016)
Printed In U.S.A. CYL 4
FUEL INJECTOR LSD2A 125 C154
7281093
177 PWM 2
INLET METERING
1 VALVE

595 of 1052
 Index Diagram
1 SH01 - INDEX
2 SH02 - UNSWITCHED BATT POWER
3 SH03 - SWITCHED POWER
4 SH04 - GROUND
5 SH05 - CAN BUS WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
6 SH06 - ENGINE CAN BUS
7 SH07 - ENGINE GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
8 SH08 - ENGINE CONTROLLER UNIT
9 SH09 - DOSING CONTROL UNIT BATT FEED, GENERAL 1000 THROUGH 1499 RED RED LEGEND
10 SH10 - HYDRAULICS
11 SH11 - CAB DISPLAY BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT CONNECTOR
12 SH12 - CAB
ORANGE/WHITE RNG/WHT 1 1
13 SH13 - CONTROLS BATT FEED, SWITCHED 1500 THROUGH 1999
14 SH14 - LIGHTS
15 SH15 - HVAC
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK PARTIAL CONNECTOR
16 SH16 - OPTIONS 1
17 SH17 - OPTIONS 2
CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN 1 1

MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL

1 1
HARNESS PART NUMBER HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
EXLF MFR SCPA 7302616 WIRE BREAK
DLX CAB 7301237 CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL WIRE BREAK
SHT1/F2 SHT1/F2

DLX FUEL 7266824 SHT1/F2

WIRE BREAK
SHT1/F2
LIGHTS 6000 THROUGH 6999 PINK PNK
BCT ENG 7242470
TAILGATE DOM 7267103 OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
SUSP JSTK 7284703
ENGINE 8000 THROUGH 8999 TAN TAN
WHL 2 SPD ADP 7159366
TRK 2 SPD ADP 7214627 COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR
DEF JUMPER 7305995
COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
Click Here For Interactive PDF S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 1 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
REVISED C161 PIN ASSIGMENTS
DESCRIPTION
103427 MPS
CHG NOTICE DWN
6
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 1 / 17
7302615
Printable Version Click Here
596 of 1052
 UNSWITCHED
BATT POWER
1240 RED/WHT
SHT11/E4

C408 1400 RED/WHT

SHT12/D3
1450 RED/WHT 1450 RED/WHT
6 6 SP7
1420 RED/WHT
SHT11/E4
FUSE RELAY CENTER
1440 RED/WHT
1110 RED/WHT SHT11/G8
2
FUSE 11 25 A GWY CTRLR
1070 RED 1120 RED/WHT 1130 RED/WHT
11A 11B 3
SP2
FUSE 13 25 A SP36 J1B
1025 RED 1160 RED/WHT 1150 RED/WHT
13A 13B 3
1180 RED/WHT AUX CTRLR
2
J2B
+12V BATTERY MEGAFUSE
100.0 Amps
HW11 1 1

T5 T4

FUSE 17 25 A
1280 RED 1235 RED/WHT SP58 1250 RED/WHT
17A 17B 2
DRIVE CTRLR
1260 RED/WHT

1010 RED
3
SHT7/G1
FUSE 4 25 A J5B
1310 RED 1140 RED/WHT
4A 4B SHT15/E8

FUSE 1 15 A
1320 RED/WHT
1A 1B SHT14/B8

BUS BAR
FUSE 2 20 A
SP26 1340 RED 1330 RED/WHT
2A 2B SHT14/D8

1350 RED/WHT

1325 RED
FUSE 20 5 A SHT14/F8
1335 RED 1345 RED/WHT
20A 20B SHT3/G8

FUSE 16 25 A
SP1 1300 RED 1035 RED/WHT
16A 16B SHT3/H8

1445 RED/WHT
SHT7/B3
FUSE 18 25 A
1190 RED 1165 RED/WHT
18A 18B SHT5/B8
1055 RED

FUSE 25 10A
1095 RED 1100 RED/WHT
25A 25B SHT9/H8

FUSE 26 15A
1220 RED 1230 RED/WHT
26A 26B SHT9/G8

FUSE 10 30A
1045 RED 1105 RED/WHT
10A 10B SHT7/E7

1460 RED/WHT
SHT16/B7
FUSE 22 25 A
1040 RED 1490 RED/WHT 1410 RED/WHT
22A 22B SHT16/F7
SP24

FUSE 24 25 A
SP60 1290 RED 1370 RED/WHT
24A 24B SHT12/F8

FRC1 FRC1
1050 RED
SHT3/D8
1030 RED
SHT7/H8

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 2 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427 MPS
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 2 / 17
7302615
Printable Version Click Here
597 of 1052
 FRC1 ENGINE 1525 RNG/WHT
SHT6/E4
ECU RELAY - G
ENG ECU CTRLR

1035 RED/WHT +12V PWR 30

1506 RNG/WHT
1 SWITCHED
SHT2/D1 G1 87 1540 RNG/WHT 1545 RNG/WHT SP54 1507 RNG/WHT

86 85
G4
SP73
1508 RNG/WHT
3
POWER
G2 G5 5

FRC1 FRC1
8005 TAN
45 ENG ECU SW SIG
1345 RED/WHT
SHT2/D1 J7A
FUSE RELAY CENTER

FUSE 21 15 A
1509 RNG/WHT 1511 RNG/WHT
21A 21B SHT7/B7

FUSE 5 25 A
1780 RNG/WHT C489
5A 5B A A MFR ACCESSORY

FUSE 6 25 A
1760 RNG/WHT 1850 RNG/WHT
6A 6B SHT12/G8
1575 RNG/WHT
SHT17/G4
FUSE 12 25 A
1790 RNG/WHT 1550 RNG/WHT
12A 12B SHT16/G7

1700 RNG/WHT
SHT11/C8
1705 RNG/WHT
SHT11/B8
1620 RNG/WHT
SHT11/G8
1940 RNG/WHT
SHT11/H8
1930 RNG/WHT
FUSE 14 5 A SHT11/H4
1805 RNG/WHT 1560 RNG/WHT 1775 RNG/WHT
14A 14B 22 AUX CTRLR SHT11/D8
1960 RNG/WHT
J2B SHT11/F8
FRC1 C428 1785 RNG/WHT
SWITCHED SHT13/H8
MFR HARN CONN 2
POWER 1950 RNG/WHT
(LT GRAY) SHT11/F4
RELAY - A 1660 RNG/WHT 1660 RNG/WHT 1590 RNG/WHT
2 2 SHT11/E4
SP42 1565 RNG/WHT
SHT17/E3
+12V PWR
1050 RED 30 FUSE 7 25 A SP65
SHT2/B1 A1 87 1765 RNG/WHT SP25 1795 RNG/WHT 1730 RNG/WHT 1735 RNG/WHT
A4 7A 7B SHT5/B8
GND
86 85
A5 A2 1725 RNG/WHT
SHT6/D7
FRC1 FRC1 FUSE 8 25 A
1580 RNG/WHT
8A 8B SHT12/F8

FUSE 23 15 A
1815 RNG/WHT 1800 RNG/WHT
23A 23B SHT7/G8

FRC1 FRC1
2055 BLK
SHT4/B8

GWY CTRLR C428

3450 LBL SP37
21 SWITCHED POWER RELAY FEEDBACK 1920 RNG/WHT 1920 RNG/WHT 1840 RNG/WHT
9 9 SHT5/D3
1830 RNG/WHT
3380 LBL SHT5/E3
4 SWITCHED POWER RELAY SIGNAL

J1A
1740 RNG/WHT SP57 1630 RNG/WHT
21 DRIVE CTRLR
J5B

1770 RNG/WHT
SHT13/F2
1710 RNG/WHT
SHT13/F2

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 3 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 3 / 17
7302615
Printable Version Click Here
598 of 1052
 ENG ECU CTRLR

2
2001 BLK GROUND
SP53 SP75
2002 BLK 2820 BLK 2805 BLK
4
2035 BLK 2320 BRN
2003 BLK 15 SP50 2235 BLK SHT10/F7 GWY CTRLR
6 DRIVE CTRLR 2370 BRN
2490 BLK SHT12/D8
T32 J7A 16 2220 BRN SP12 2230 BRN
2004 BLK
ECU CASE GND SHT10/G7 17 SENSOR GROUND
1 2155 BLK J5B 2190 BRN
SHT17/F5 SHT10/E7
J1B
2880 BLK 2180 BRN
SHT9/F8 SHT7/D7
2150 BRN
SHT7/G7
2430 BRN
2080 BLK SHT7/C7
SHT5/D3

2070 BLK
SHT5/E3
T6
2920 BLK 1 BATT GND
SHT11/G8 C408
MFR HARN CONN 1 (BLACK)
2940 BLK SP4 2950 BLK 2950 BLK
SHT11/G4 10 10

2960 BLK
SHT11/E4

2250 BLK 2510 BLK SP3 2110 BLK

SHT11/D4 16
GWY CTRLR 2500 BLK
15
2765 BLK
SHT14/H8
J1B
2745 BLK
SHT15/D7
T8
2790 BLK 1 BATT GND
2540 BLK SHT12/D8
2860 BLK 16
SHT17/D4
AUX CTRLR SHT16/E7
2780 BLK
2890 BLK 2550 BLK 2090 BLK
SHT17/H4 15
2065 BLK SP28 2730 BLK
SHT11/C8 J2B SHT12/E8
2930 BLK C428
SHT11/E8 MFR HARN CONN 2 (LT GRAY)
2830 BLK 2900 BLK 2900 BLK
SHT16/D5 1 1
2700 BLK SP47
SHT11/F8
2785 BLK 2770 BLK
SHT16/B7 SHT16/H6 T10
SHT7/F3
2015 BLK 1
ENGINE GROUND
2200 BLK
SHT10/F4

2620 BLK C489 2720 BLK

SHT14/C4 MFR ACCESSORY B B

2650 BLK
SHT13/F8 C103
TAILGATE HARN T1
2640 BLK 2600 BLK 2600 BLK SP6 2390 BLK BATT GND
SHT14/C4 B B 1 AUX CTRLR
SP51
2610 BLK
SHT14/E4 2400 BLK 2185 BRN
SHT7/E4 SHT17/E7 17 SENSOR GROUND
2630 BLK
SHT14/B4 2405 BLK
SHT7/D4 J2B

2455 BLK
SHT16/D6

2710 BLK SP27 2300 BLK

SHT5/B8

2715 BLK
SHT6/D7

2290 BLK
SHT15/B8
2505 BLK
SHT17/G4
2045 BLK 2295 BLK
SHT14/B8 SHT7/D7
2115 BLK
SHT14/D8
2055 BLK
SP55 2105 BLK
SHT3/C1
2030 BLK
SHT15/F8
2005 BLK
SHT7/G7
2120 BLK
SHT14/E8

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 4 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427 MPS
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 4 / 17
7302615
Printable Version Click Here
599 of 1052
 CAN BUS
* DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)

RE016 RE019 C479

C408
120 OHM 0.5 W RESISTOR MFR HARN CONN 1 (BLACK) 120 OHM 0.5 W RESISTOR LEFT PANEL
GWY CTRLR R3-1 SP19 SP18 (BLACK)
TP-09 9260 PUR TP-09 TP-10 9230 PUR TP-10 SP31 TP-12 TP-12 TP-16 9220 PUR TP-16 TP-01 TP-01 TP-03 TP-03
SP39 TP-05 TP-05 SP35 TP-07 TP-07 R1 TP-08 9460 PUR TP-08
9250 PUR 9220 PUR 9410 PUR 9430 PUR 9450 PUR
CAN LO 8 4 4 4 CAN LO

SP30 SP17 SP38 SP34

CAN HI 9160 PUR/WHT 9130 PUR/WHT 9150 PUR/WHT 9120 PUR/WHT 9120 PUR/WHT 9310 PUR/WHT 9330 PUR/WHT 9350 PUR/WHT 9360 PUR/WHT
9 3 3 3 CAN HI
R3-2 SP20 TP-15 R2
TP-02 TP-04 TP-06
J1B
C479

C503
RH DLX PANEL
DRIVE CTRLR 9440 PUR TP-06
9290 PUR TP-15 4 CAN LO
8 CAN LO
9190 PUR/WHT 9340 PUR/WHT
9 CAN HI 2 CAN HI
TP-11
J5B
C503

* C450 C460
RIGHT JOYSTICK
RIGHT JOYSTICK CONN RIGHT JOYSTICK
1830 RNG/WHT 1830 RNG/WHT +12V PWR
SHT3/B1 1 1 1 1
2070 BLK 2070 BLK GND
SHT4/G8 2 2 2 2
9320 PUR/WHT TP-04 9560 PUR/WHT CAN HI
3 3 3 3
AUX CTRLR 9420 PUR 9660 PUR CAN LO
4 4 4 4
TP-11
9280 PUR
8 CAN LO

9180 PUR/WHT
9 CAN HI * C449 C459
LEFT JOYSTICK
LEFT JOYSTICK CONN LEFT JOYSTICK
J2B 1840 RNG/WHT 1840 RNG/WHT +12V PWR
SHT3/C1 1 1 1 1
2080 BLK 2080 BLK GND
SHT4/G8 2 2 2 2
9300 PUR/WHT TP-02 9540 PUR/WHT CAN HI
3 3 3 3
9400 PUR 9640 PUR CAN LO
4 4 4 4

SUSP SEAT JOYSTICK HARNESS

AUX CTRLR C426

Remote Run Tool, ACD
TP-30 9500 PUR/WHT TP-30
CAN HI 14 A A CAN HI

9600 PUR
CAN LO 20 B B CAN LO

J2B
3095 LBL
REMOTE RUN KEY 24
J2A

GWY CTRLR
3090 LBL 3085 LBL
REMOTE RUN KEY 21 D D REMOTE RUN KEY
SP93

J1B
C C

1735 RNG/WHT
SHT3/D1 E E SWITCHED POWER

1165 RED/WHT
SHT2/D1 F F UNSWITCHED POWER

2710 BLK
SHT4/C6 G G GROUND

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 5 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 5 / 17
7302615
Printable Version Click Here
600 of 1052
 ENGINE
CAN BUS
RE014
120 Ohm Terminator DOSING CONTROL UNIT
120 OHM 0.5 W RESISTOR
ENG ECU CTRLR Resistor internal to
R5-1
TP-17 TP-17 TP-18 TP-18
SP81 TP-20
SP90 TP-22 SP67 TP-24 TP-24 SP71 TP-26 TP-26 SP70 TP-28 Controller TP-28
9200 PUR 9215 PUR 9415 PUR TP-20 TP-22 9210 PUR 9265 PUR 9275 PUR 9245 PUR
ENG CAN LO 47 65 ENG CAN LO

SP82 SP91 SP68 SP72 SP69

9100 PUR/WHT 9115 PUR/WHT 9315 PUR/WHT 9110 PUR/WHT 9165 PUR/WHT 9175 PUR/WHT 9145 PUR/WHT
ENG CAN HI 48 66 ENG CAN HI
R5-2
J7A C121
TP-19 TP-21 TP-23 TP-25 TP-27

9105 PUR/WHT
C163

9205 PUR
NOx PRETREATMENT
1645 RNG/WHT
1
2835 BLK
2
9295 PUR TP-27
3
9195 PUR/WHT
GWY CTRLR 4
2870 BLK 2875 BLK
TP-19 SHT9/F8 5
20 ENG CAN LO SP78
C163

14 ENG CAN HI
C164
J1B
NOx POST TREATMENT
1635 RNG/WHT
1
2815 BLK
2
TP-25
9285 PUR
3
9185 PUR/WHT
4
5

C164
1525 RNG/WHT
SHT3/H1 SP76

C162 C161
B
DEF JUMPER CONN DEF TANK
C169 1640 RNG/WHT 1640 RNG/WHT
4 4 1
ENGINE CAN 9225 PUR TP-23 TP-31
9225 PUR
TP-31
1 1 4 ENG CAN LO
1725 RNG/WHT 9125 PUR/WHT 9125 PUR/WHT
1 SHT3/D1 2 2 3 ENG CAN HI
2825 BLK 2825 BLK
SHT9/F8 3 3 2
2715 BLK
2 SHT4/C6 C161
SUSP SEAT JOYSTICK HARNESS
TP-21 9155 PUR/WHT
ENG CAN HI 3

9255 PUR
ENG CAN LO 4
DOSING CONTROL UNIT

TP-29 TP-29
9720 PUR/WHT
CAN HI DCU DIAGNOSTIC 5 82 CAN HI DCU DIAGNOSTIC

9820 PUR
CAN LO DCU DIAGNOSTIC 6 60 CAN LO DCU DIAGNOSTIC

C169
C121

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 6 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 6 / 17
7302615
Printable Version Click Here
601 of 1052
 T7 STARTER
FRC1 STARTER
RELAY - M
1
1
R ENGINE
C111
MFR-BCT HARN CONN T21 S
1030 RED
SHT2/A1 M1 87 8200 TAN 8220 TAN
30 M4 A A

8210 TAN 85 3560 LBL

M5 M2 B B T9 B
86
1
FRC1 FRC1

1800 RNG/WHT 1800 RNG/WHT

SHT2/F7
SHT3/C1 C C
ALTERNATOR
2005 BLK 1015 RED
SHT4/B8

GWY CTRLR 1
T43
STARTER RELAY SIGNAL 7 1
3560 LBL T11
STARTER RELAY FEEDBACK 22
2150 BRN GND 1
SHT4/G3 B
AIR FILTER T12
3150 LBL SWITCH (NC) 2015 BLK
AIR FILTER SENDER SIGNAL 16 A SIG
SHT4/E3

C405

3105 LBL
RIGHT TAILGATE FAN RELAY FEEDBACK 25
3100 LBL
LEFT TAILGATE FANS RELAY FEEDBACK 12

TAILGATE FANS RELAY-C C104 LEFT TAILGATE FAN

TAILGATE FANS CONN FUSE 15 A
8110 TAN 8110 TAN 8125 TAN
C4 1 1 A B A
87
SHT2/C1
1105 RED/WHT
C1 C3
C171 C171 M
30 87a 2400 BLK 2400 BLK
8100 TAN SHT4/D6 2 2 B
C5 C2
86 85 C119
RIGHT TAILGATE FAN
FRC1
FRC1 FUSE 15 A
8105 TAN 8105 TAN 8135 TAN
TAILGATE FAN RELAY OUTPUT 9 3 3 A B A

J1A SHT4/B6
2295 BLK C172 C172 M
2405 BLK 2405 BLK
SHT4/C6 4 4 B
C355
FUEL HARN C113

3180 LBL 3180 LBL HAND THROTTLE

FUEL SENDER SIGNAL 12 C C A
FUEL SENDER F
(30 - 270 OHM) SHT12/C7 E
2180 BRN 2180 BRN D
SHT4/G3 D D B C428
5690 YEL +5V PWR
MFR HARN CONN 2 (LT GRAY) C
C406 3690 LBL
3690 LBL SIG
THROTTLE PRIMARY SIGNAL 10 6 6 A
2430 BRN 2690 BRN GND
SHT4/G3 2 SHT12/D5 B
C120
T
ENGINE TEMP C114
3110 LBL
ENGINE TEMP SIGNAL 18 1 SENSOR (950-4400 OHM)
8007 TAN C120
IGN SW ON 4
INTAKE HEATER
J1B 8020 TAN INTAKE HEATER FUSE CONTACTOR
SHT9/F8 SP74
ENG ECU CTRLR +12V PWR 150 AMPS
1 1060 RED 1 1 1065 RED 1
8008 TAN 87 1 8515 TAN
SP77 8500 TAN 1
IGN SW ON 19 C100 T29 T26 T27 T28 30
2865 BRN GND C100 T30 T14
WATER IN FUEL RETURN 34 2 1445 RED/WHT 1 85 1
WATER IN FUEL SENSOR SHT2/D1 8505 TAN 1
T41 86 T40
(FUEL FILTER)
3865 LBL SIG
T31
WIF SENSOR 9 1
8510 TAN
PRE HEATER RELAY DRIVER 56
C118 KL87 SHT8/B6
1511 RNG/WHT
SHT3/G1 1 1 SHT8/C6
8013 TAN
MAFS FREQU SIGNAL 28 2 2 SHT8/G3
8014 TAN
AIR INLET TEMP 35 3 3 SHT8/F3
1 3420 LBL
4 4 SHT8/H7
T42
J7A ENG-CROSSOVER

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 7 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427 MPS
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 7 / 17
7302615
Printable Version Click Here
602 of 1052
 ENGINE CONTROL UNIT

J7B
ENG ECU CTRLR

GLOW PLUG FEEDBACK

SHT7/B5 79 GLOW PLUG FEEDBACK
EXHAUST GAS TEMP SENSOR (BEFORE TURBO)
EXHAUST GAS TEMP SENSOR 2 RETURN 23 1
EGR VALVE DC MOTOR

T
EXHAUST GAS TEMP SENSOR 2 6 2
1 64 VREF 3 EGR C131
5 16 EGR POSITION SENSOR SIGNAL
3 72 EGR SENSOR RETURN GND
OPEN
MAF SENSOR
4 MAF FREQ
SHT7/B5 1
6 92 EGR H BRIDGE POSITIVE
MASS AIR FLOW SENSOR 5V 37 2
2 93 EGR H BRIDGE NEGATIVE MASS AIR FLOW SENSOR GND 20 3
MAF TEMP
C151 SHT7/B5 4
C136
COOLANT TEMP SENSOR
COOLANT TEMP SENSOR RETURN
OIL PRESSURE & TEMPERATURE SENSOR
1 45
OIL TEMP SENSOR 4 2

T
2 9 COOLANT TEMP SENSOR
VREF 3 OIL PRESSURE 65 3
C149 T
OIL PRESSURE SENSOR 11 4 P
FUEL TEMP SENSOR OIL PRESSURE & TEMP RETURN GND 48 1
1 10 FUEL TEMP SENSOR
C137
T

2 46 FUEL TEMP SENSOR RETURN GND

C148 INTAKE MANIFOLD TEMPERATURE

AIR INTAKE TEMP SENSOR RETURN 69 1
KNOCK SENSOR 1 SHIELD-01

T
SHIELD-01 AIR INTAKE TEMP SENSOR 94 2
1 30 ENGINE BLOCK ACCELEROMETER #1 RETURN
C150
2 31 ENGINE BLOCK ACCELEROMETER #1

ENGINE BLOCK ACCELEROMETER #1 SHIELD

INTAKE MANIFOLD PRESSURE SENSOR
3 28
VREF 2, INTAKE PRESSURE SENSOR 61 1
C147
INTAKE MANIFOLD PRESSURE SENSOR 12 3
KNOCK SENSOR 2 P
SHIELD-02 SHIELD-02
1 33 ENGINE BLOCK ACCELEROMETER #2 RETURN INTAKE MANIFOLD PRESSURE RETURN GND 67 2
2 32 ENGINE BLOCK ACCELEROMETER #2 C138
3 29 ENGINE BLOCK ACCELEROMETER #2 SHIELD
INJECTOR #1
C146 FUEL INJECTOR #1 HSDA 27 1

CRANKSHAFT POSITION SENSOR SHIELD-03

SHIELD-03
1 36 CRANKSHAFT SENSOR NEG FUEL INJECTOR #1 LSD1A 26 2
2 60 CRANKSHAFT POSITION SENSOR C139
3 87 CRANKSHAFT SENSOR SHIELD
INJECTOR #2
C145 FUEL INJECTOR #2 HSDB 50 1

CAMSHAFT SENSOR
VREF 1 CAMSHAFT SENSOR
1 SHT7/B5 FUEL INJECTOR #2 LSD2B 74 2
2 59 CAM SHAFT POSITION SENSOR C140
3 47 CAM SHAFT POSITION SENSOR RETURN
INJECTOR #3
C144 FUEL INJECTOR #3 HSDB 51 1

RAIL PRESSURE SENSOR

3 38 VREF 1 RAIL PRESSURE SENSOR FUEL INJECTOR #3 LSD1B 75 2
1 35 RAIL PRESSURE SENSOR C141
P
RAIL PRESSURE SENSOR RETURN
INJECTOR #4
2 19
FUEL INJECTOR #4 HSDA 3 1
C143

FUEL INJECTOR #4 LSD2A 25 2

INLET METERING VALVE
VREF 1 INLET METERING VALVE
1 SHT7/B5 C142

2 77 INLET METERING VALVE (PWM)

C154
J7B
J7B

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 8 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 8 / 17
7302615
Printable Version Click Here
603 of 1052
 HOSE HEATER MAIN

SHT2/C1
1100 RED/WHT
30
DOSING CONTROL
8090 TAN

86
87

85
2310 BRN
UNIT
RL010 RL010
8310 TAN

2975 BLK 1 T33

DCU CASE GND
2915 BLK

DOSING CONTROL UNIT

SP62
1230 RED/WHT 1245 RED/WHT
SHT2/C1 5 HOSE RELAY MAIN SIGNAL 93
1265 RED/WHT
6
1255 RED/WHT
73
CAN JUMPER 67
1275 RED/WHT
51
7998 WHT
CAN JUMPER 68
2880 BLK SP63 2925 BLK
SHT4/G8 1
CAN JUMPER 89 C123
2825 BLK 2935 BLK
SHT6/D4 2 HOSE 1 HEATER
7999 WHT 8320 TAN
2870 BLK CAN JUMPER 90 2
SHT6/F4 2945 BLK
7
8120 TAN
2855 BLK SP87 1
29 HOSE 1 HEATER
8020 TAN 8340 TAN
C123
HOSE 1 RELAY FB SP88
SHT7/C7 22 IGNITION SIGNAL
72
2170 BRN 8330 TAN
1 75 TANK HEATER VALVE GND 30 2955 BLK
87 SP86
TANK HEATING
VALVE 8540 TAN HOSE 1 HEATER 8550 TAN

2985 BLK
4 92 94 86 85

2965 BLK
TANK HEATING VALVE SIG
C155 RL011 RL011
Shield Shield C124
8850 WHT RELAY GROUND 2135 BRN 2145 BRN
1 80 RED AGENT VALVE HIGH 53 HOSE 2 HEATER
SP85 8240 TAN
REDUCTION AGENT 2
METERING VALVE 8950 BLK 2140 BRN
2 58 RED AGENT VALVE LOW
SP92 8140 TAN
C156 2165 BLK 8260 TAN 1
59 HOSE 2 RELAY FB
49 HOSE 2 HEATER
RED AGENT SHIELD SP89 C124
2025 BRN C125
CATALYST 2 61 CAT TEMP SCR GND 8250 TAN
TEMPERATURE SCR 30 HOSE 3 HEATER
T 87 8350 TAN
INLET 2
8900 TAN
1 83 CAT TEMP SCR INLET 8560 TAN
HOSE 2 HEATER 50 86 85
C157 8150 TAN
2125 BRN RL012 RL012 1
C125

HOSE 3 HEATER

8370 TAN 8360 TAN

HOSE 3 RELAY FB 27 30
2050 BRN SP61 87
2 9 ENV TEMP GND
ENVIRONMENTAL 8600 TAN C122
TEMPERATURE T HOSE 3 HEATER 28 86 85 SUPPLY MODULE
8800 TAN
1 31 ENV TEMP SIG RL013 RL013
C159 1690 RNG/WHT HEATER BATT+
SM HEATER BATT 4 11
2075 BRN SM HEATER SIGNAL 8650 TAN HEATER SIGNAL
CATALYST 2 12 3 12
CAT TEMP DOC INLET
TEMPERATURE DOC 1695 RNG/WHT PUMP MOTOR BATT +
T +5V POWER 55 3
INLET 8530 TAN CAT TEMP DOC SM PUMP MOTOR 8700 TAN PUMP MOTOR CONTROL SIGNAL
1 34 INLET CONTROL SIGNAL
76 2
2095 BRN PUMP MOTOR GND
C160 SM PUMP MOTOR GND 54 4
1680 RNG/WHT PURGING PUMP BATT +
SM PURGING PUMP BATT+ 77 5
8750 TAN PURGING PUMP SIGNAL
SM PURGING PUMP SIGNAL 78 6
1685 RNG/WHT PRESSURE SENSOR BATT+
SM PRESSURE SENSOR BATT+ 17 10
3000 LBL PRESSURE SENSOR SIGNAL
SM PRESSURE SENSOR SIGNAL 39 9
2085 BRN PRESSURE SENSOR GND
SM PRESSURE SENSOR GND 40 8
C121 C121 C122

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 9 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 9 / 17
7302615
Printable Version Click Here
604 of 1052
 HYDRAULICS

2220 BRN GND

GWY CTRLR SHT4/H3 B C425
HYDRAULIC TEMPERATURE SENDER
T B B
500 - 3000 OHM (8 VOLT)
3220 LBL SIG 4200 LGN C308
HYD TEMP SIGNAL 32 A A A A
BRAKE
C108
SOLENOID 9.8
2200 BLK 2200 BLK
SHT4/D6 C C B OHM 12 V TRACK 2 SPEED ADAPTER
3320 LBL SIG (SEE ADDITIONAL OPTIONS DWG)
HYD FILTER DIFF PRESS 34 A C308
HYDRAULIC OIL FILTER SWITCH
2320 BRN GND (NC)
SHT4/H3 B WHEEL 2 SPD ADP HARNESS 7159366
TRACK 2 SPD HARNESS 7243409
C112
TRACK SINGLE SPD BRAKE ADP HARNESS 7234968
4010 LGN SIG
1
HYDRAULIC FAN SOLENOID
2910 BRN GND 7.2 OHM 12 V
HYDRAULIC FAN GROUND 18 2
C446

2410 BRN GND

HYD LOCK VALVE SOL GROUND 1 2
HYDRAULIC LOCK SOLENOID
4410 LGN SIG 9.8 OHM 12 V
1
J1A
C420

2190 BRN GND

SHT4/G3 B
P HYDRAULIC CHARGE
3190 LBL SIG
C PRESSURE 0.5-7.5V
5190 YEL +8 PWR
A
C105
4200 LGN
J1B
19

13

23

6
HYD CHARGE PRESS
SENDER SIGNAL
HYDRAULIC FAN
SIGNAL
HYD LOCK
SOLENOID SIGNAL

HYD CHARGE PRESS

SENDER POWER
TRACTION
SOLENOID OUTPUT

4330 LGN GND

AUX CTRLR 1
FRONT ROD SOLENOID (MALE)
FRONT ROD SOLENOID 2330 BRN SIG 3.3 OHM PWM
GROUND
18 2
GWY CTRLR
C418
4340 LGN GND
1
FRONT BASE SOLENOID (FEMALE)
FRONT BASE SOLENOID 2340 BRN SIG 3.3 OHM PWM
1 2
GROUND
J2A C419

J2B
19

13
FRONT ROD
SOLENOID SIGNAL

FRONT BASE
SOLENOID SIGNAL
AUX CTRLR

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 10 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 10 / 17
7302615
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605 of 1052
 1940 RNG/WHT 1
LEFT PANEL BUZZER CAB DISPLAY
SHT3/E1
T13
7040 WHT 1
C499
T2 PTOL CONN

C479 1930 RNG/WHT SWITCHED POWER

LEFT PANEL (BLACK) SHT3/E1 1

2940 BLK GROUND

SHT4/F8 3
BUZZER GWY CTRLR
10 C408
MFR HARN CONN 1 (BLACK)
2920 BLK GROUND 3030 LBL 3030 LBL PTOL OUTPUT
SHT4/G8 2 PTOL SWITCH 20 1 1 2
1440 RED/WHT UNSWITCHED POWER 2380 BRN 2380 BRN PTOL LED
SHT2/G1 1 PTOL LED 19 12 12 4
1620 RNG/WHT SWITCHED POWER
SHT3/E1 5 C499
C500
3400 LBL LEFT BLINKER INPUT RH KEY SWITCH CONNECTOR
SHT16/F4 11

3500 LBL RIGHT BLINKER INPUT 8130 TAN 8130 TAN START
SHT16/F4 8 START ENGINE 24 2 2 2

1960 RNG/WHT J1A

SHT3/E1 6

SW9
3040 LBL 3040 LBL RUN/ENTER SWITCH
TRAVEL CONTROL SWITCH(OPTIONAL) RUN/ENTER 22 14 14 4

2700 BLK 3650 LBL TRAVEL CONTROL INPUT J1B

SHT4/E8 2 3 7 1950 RNG/WHT SWITCHED POWER
SHT3/D1 5
6
1
1420 RED/WHT UNSWITCHED POWER
5 4 SHT2/G1 1
3600 LBL PARK BRAKE INPUT
SW9 SW9 9
SW1 2960 BLK GROUND
SHT4/F8 3
BRAKE SWITCH 6
C500
2930 BLK 12 C503
SHT4/E8 2 1 RH DLX PANEL
C479 SHT5/G1

5 6 1590 RNG/WHT SWITCHED POWER

SHT3/D1 5
4
3 1240 RED/WHT UNSWITCHED POWER
SW1 SHT2/H1 1
SW1
C480 2250 BLK GROUND
1775 RNG/WHT SHT4/F8 3
SHT3/E1 LEFT PANEL CONN (GRAY)

3620 LBL DOOR SIGNAL

6
SHT12/D3 12
C503 SHT5/F1

11

10

3610 LBL PARK BRAKE OUTPUT

2
8

SW12 6
DESOX INHIBIT SWITCH(OPT KIT)

2065 BLK 8070 TAN DESOX INHIBIT

SHT4/E8 2 4 9
1700 RNG/WHT 8050 TAN
SHT3/E1 7 9 4
1705 RNG/WHT 8055 TAN DESOX INHIBIT LAMP
SHT3/E1 10 8 5
8060 TAN
3 1
SW12 1
C480
SW12

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 11 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHTPrintable
11 / 17
7302615
Version Click Here
606 of 1052
 CAB
* DLX CAB HARN 7301237 ONLY
(NOT IN STD CAB HARN 7303755)

C438
*
MFR HARN CONN 3 (DK GRAY) 2795 BLK GND
1850 RNG/WHT 1850 RNG/WHT 1
SHT3/F1 2 2 C212
1375 RED/WHT +12V PWR POWER SOCKET
2
C212
C408
MFR HARN CONN 1 (BLACK) DOME LIGHT

SHT2/B1
1370 RED/WHT
7 7
1370 RED/WHT
SP45 1390 RED/WHT * 1
C129 T37
CAB ACCESSORY
1210 RED/WHT 2010 BLK
A A +12V BATT PWR 1
1580 RNG/WHT 1580 RNG/WHT SP8 1865 RNG/WHT SP41
SHT3/D1 5 5 B B +12V SW PWR
* T38

2800 BLK
C C GND

1510 RNG/WHT
SHT16/C2

1885 RNG/WHT
SHT16/B3

2730 BLK 2730 BLK SP44 2210 BLK

SHT4/E3 11 11 SHT16/C2

2885 BLK
SHT16/B3

2060 BLK
SHT13/H8
C428
MFR HARN CONN 2 (LT GRAY) C667
SHT4/E3
2790 BLK
14 14
2790 BLK * DOOR HARNESS
(SEE ADDITIONAL
2690 BRN
SHT7/C4 OPTIONS DWG)
2370 BRN 2370 BRN 2375 BRN
SHT4/H3 4 4 SEATBAR 1 1 WIPER SWITCH, MOTOR SWITCHED POWER
SP56 SENSOR 3620 LBL
SHT11/D8 4 4 DOOR SIGNAL

2845 BLK
1400 RED/WHT
GWY CTRLR GND
SHT2/H1 5 5 DOOR UNSW PWR
A
3370 LBL 3370 LBL SIG
6 6
SEATBAR SENSOR SIGNAL 11 5 5 B 2840 BLK
+5V PWR
2 2 WIPER MOTOR GROUND
C
5100 YEL 5370 YEL SP52 5375 YEL 7310 WHT
5V CTRLR POWER 24 3 3 3 3 WASHER SIGNAL
C482

J1B 5690 YEL

SHT7/D4

HARNESS WASHER PUMP

* C252
7253378
2845 BLK GND
B B 2
WASHER
MOTOR
7310 WHT PWR
A A 1
C253

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 12 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 12 / 17
7302615
Printable Version Click Here
607 of 1052
 * SW4
HAND/FOOT (ACS)
H/ISO (SJC, AWS)
CONTROLS
SWITCH
1785 RNG/WHT
SHT3/E1 2 1
6
2060 BLK
SHT12/D1 5
4
SW4 3
SW4
DRIVE CTRLR C438
MFR HARN CONN 3 (DK GRAY)
4235 LGN 4235 LGN
HAND CONTROL LIGHT 8 7 7

4275 LGN 4275 LGN

FOOT CONTROL 6 8 8

4550 LGN 4550 LGN

FOOT CONTROL SIGNAL 21 9 9 C536
RIGHT SWASHPLATE CONN RIGHT SWASHPLATE
2810 BRN 2810 BRN
4 4 A
C103
1710 RNG/WHT 1710 RNG/WHT
TAILGATE HARN DRIVE CTRLR SHT3/B1 1 1 B
7100 WHT 7100 WHT T19 3810 LBL 3810 LBL
BACKUP ALARM POWER 17 C C RIGHT SWASHPLATE ANGLE 10 3 3 C
1 BACK UP ALARM 5890 YEL SP84 5810 YEL
J5A 2650 BLK 1 SENSOR SUPPLY +5V 23 2 2 C543
SHT4/D8
T20 2890 BRN
MAIN SENSOR GND 17 SP83
C537
LEFT SWASHPLATE CONN LEFT SWASHPLATE
2860 BRN 2860 BRN
4 4 A
1770 RNG/WHT 1770 RNG/WHT
SHT3/B1 1 1 B
GWY CTRLR 3860 LBL 3860 LBL
TILT SPOOL LOCK 7.8 OHM 12V LEFT SWASHPLATE ANGLE 18 3 3 C
TILT SPOOL LOCK 2980 BRN 5860 YEL
SOLENOID GND 10 3 2 2 C542

LIFT SPOOL LOCK 2990 BRN

C501
2 1 A22 PUMP CONN RIGHT FORWARD DRIVE
SOLENOID GND
4260 LGN 4260 LGN
J1A C421 RIGHT FWD DRIVE 26 1 1 1

TILT SPOOL LOCK 4980 LGN 2660 BRN 2660 BRN

7 LIFT SPOOL LOCK 7.8 OHM 12V RIGHT REV DRIVE 25 2 2 2
SOLENOID SIG
3 C546
LEFT REV DRIVE 19 RIGHT REVERSE DRIVE
LIFT SPOOL LOCK 4990 LGN 4250 LGN 4250 LGN
SOLENOID SIG 5 1 3 3 1
J1B C422 LEFT FWD DRIVE 7
2650 BRN 2650 BRN
J5B 4 4 2
C547
LEFT REVERSE DRIVE
4280 LGN 4280 LGN
5 5 1
RIGHT FWD GND 26
2680 BRN 2680 BRN
6 6 2
RIGHT REV GND 27
C545
LEFT REV GND 18 LEFT FORWARD DRIVE
4270 LGN 4270 LGN
7 7 1

2670 BRN 2670 BRN

LEFT FWD GND 10 8 8 2
C544
C474
BRAKE CONN
4210 LGN
BRAKE LIGHT SIG 9 A A
J5A

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 13 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427 MPS
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 13 / 17
7302615
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608 of 1052
 6100 PNK
C434-1
A
LIGHTS
SIG

37 WATT

C408
2735 BLK GND
MFR HARN CONN 1 (BLACK) B LEFT FRONT
2765 BLK 2765 BLK SP14 2750 BLK WORKLIGHT
SHT4/F3 9 9 B
GND

50 WATT

6110 PNK SIG

A
C434-2

C435-1
6000 PNK 6000 PNK 6120 PNK
8 8 SIG
A
SP15
FRONT WORK LIGHTS 37 WATT
RELAY - RC1
C438
2760 BLK GND
1350 RED/WHT MFR HARN CONN 3 (DK GRAY) B RIGHT FRONT
SHT2/E1 30 6620 PNK SP23 6610 PNK 6610 PNK 6130 PNK WORK LIGHT
87 13 13 A
SIG
SP64
86 85 50 WATT

2705 BLK GND

RC1 RC1 B
C435-2
2120 BLK
SHT4/B8

6630 PNK
6320 PNK

FRONT WORK LIGHTS 2610 BLK GND

SHT4/D8 2
RELAY - RC2
C103 RIGHT REAR
1330 RED/WHT
30 TAIL LIGHT
SHT2/E1 TAILGATE HARN
87 6340 PNK SP10 6310 PNK 6310 PNK
SP49
6320 PNK SIG
A A 1
86 85 C603

RC2 RC2
2115 BLK 6330 PNK SIG
SHT4/B8 1
LEFT REAR
GWY CTRLR TAIL LIGHT
2640 BLK GND
SHT4/D8 2
MRKR LIGHT PWR RELAY SIGNAL 5
C602
3460 LBL
MRKR LIGHT PWR RELAY FEEDBACK 31

REAR LIGHT RELAY SIGNAL 17 T16 TERMINAL (-)

2620 BLK
3440 LBL SHT4/D8
GND 1
REAR LIGHT RELAY FEEDBACK 28
RIGHT REAR
6210 PNK

FRC1 WORK LIGHT

J1A
REAR LIGHT 6210 PNK SIG 1
RELAY - E T15 TERMINAL (+)

1320 RED/WHT T17 TERMINAL (+)

SHT2/E1 E1 87 6200 PNK 6200 PNK 6220 PNK
30 E4 H H SIG 1
SP96
85 LEFT REAR
E5 E2 WORK LIGHT
86
2630 BLK GND 1
SHT4/C8
FRC1 FRC1 T18 TERMINAL (-)
2045 BLK
SHT4/B8

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 14 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 14 / 17
7302615
Printable Version Click Here
609 of 1052
 2440 BLK GND
* HVAC
2

HVAC DUCT FAN

* DLX CAB HARN 7301237 ONLY
M (NOT IN STD CAB HARN 7303755)
7440 WHT SIG
1
C610

2560 BLK
*
C
7420 WHT POTENTIOMETER (TEMP
A
CONTROL SWITCH)
7425 WHT
B
C483

*
D
2130 BLK HEATER VALVE
C
7430 WHT
A
SP48
C635

2030 BLK
SHT4/B8

BLOWER MOTOR
FRC1
HVAC RELAY-B
C438
MFR HARN CONN 3 *
SW10
BLOWER SWITCH
* HIGH
7530 WHT
(DK GRAY) 1
1140 RED/WHT 1500 RNG/WHT 1500 RNG/WHT 2 7520 WHT MED
SHT2/E1 B1 87 10 10 5 1 2
30 B4 4 7510 WHT
LOW
SW10 3
85
B5 B2 3
86
7050 WHT

FRC1 FRC1 SW10 M

7410 WHT
4
GWY CTRLR
C611

HVAC RELAY SIGNAL 3

7400 WHT
3050 LBL
HVAC RELAY FEEDBACK 30

2745 BLK 2745 BLK 2580 BLK

SHT4/F3 11 11
SP16 2100 BLK

SW11
1
3

C
SP40 * THERMOSTAT

AC SIGNAL MONITOR 11
7021 WHT 7020 WHT
12 12
7020 WHT
1 *
2570 BLK
J1A 2
7015 WHT
3
C630
SW11
AC SWITCH

7023 WHT
B
AC EVAPORATOR
SWITCH 7024 WHT 7025 WHT SIG
A 1
D4

C350 MAGNET CLUTCH

2290 BLK 2280 BLK (COMPRESSOR)
SHT4/C6
GND
2
C486

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 15 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 15 / 17
7302615
Printable Version Click Here
610 of 1052
 C355 C428
# FUEL HARN MFR HARN CONN 2 (LT GRAY)

POWER BOB
1 SIG
4470 LGN
E E
4470 LGN
11 11
4470 LGN
OPTIONS 1
CLOSE
2470 BLK 2770 BLK 2770 BLK
2 GND SW5
C607
SP33
B B SHT4/E6
* POWER BOBTACH SWITCH # DLX FUEL HARN 7266824 ONLY
# 4480 LGN 4480 LGN 4480 LGN 1380 RED/WHT 1
(NOT IN STD FUEL HARN 7149219)
1 SIG F F 10 10 2
3 DLX CAB HARN 7301237 ONLY
POWER BOB
OPEN 2480 BLK SW5
* (NOT IN STD CAB HARN 7303755)
GND
2 SW5
C606
LEFT HANDLE 6010 PNK 6010 PNK
13 13
LIFT (ACS/AHC ONLY) LEFT HANDLE (FLASHER) 5 WAY
(SEE ADDITIONAL OPTIONS DWG) 1550 RNG/WHT 1550 RNG/WHT
SHT3/F1 12 12

C438 1405 RED/WHT

SHT17/D6
MFR HARN CONN 3 (DK GRAY)
HANDLE LOCK (ACS ONLY) 1410 RED/WHT 1410 RED/WHT SP43 1430 RED/WHT
SHT2/B1 1 1 X T3
* FLASHER
1200 RED/WHT L
FLOAT (ACS/AHC ONLY)

3500 LBL
T3
SHT11/F8 D14
SP21 6500 PNK 6500 PNK 6530 PNK
RIGHT POSTION SWITCH
6 6

PADDLE
SP22 6400 PNK 6400 PNK
D13
6430 PNK
* SW2
3 3 BEACON SWITCH
3400 LBL

6510 PNK
6410 PNK
B SHT11/G8 1
6415 PNK SW3 2
C103
LEFT POSITION SWITCH
D
6515 PNK TAILGATE HARN * HAZARD SWITCH
A
E E 1
C411 EURO TAIL LIGHTS 2 6
TRIGGER
(SEE ADDITIONAL
OPTIONS DWG) D D 3 SW2 SW2

2780 BLK 2780 BLK 4

SHT4/E3 4 4 5 6 2850 BLK SP46
2725 BLK

* SW6
BUCKET POSITION SWITCH
SW3
(PINS 3 & 6
SW3

4450 LGN 4455 LGN 4455 LGN INTERNALLY INSULATED) 6570 PNK
BUCKET A SIG 5 5 1
POSITION 2
D3

SOLENOID 3
9.8 OHM B GND
2450 BLK 2455 BLK
SHT4/C6 4 SHT17/F6
2905 BLK

2970 BLK 6700 PNK

*
C423 6 5 SHT17/F3 E E
2810 BLK 2420 BLK C670
SW6 SW6 SHT17/D4 D D
6440 PNK BEACON/FLASHER
LEFT HANDLE F F
2830 BLK
SHT4/E8
EXTERIOR HARNESS
LIFT (ACS/AHC ONLY) 6540 PNK
B B (SEE ADDITIONAL
LEFT HANDLE (HORN) 2 WAY AUX CTRLR OPTIONS DWG)
(SEE ADDITIONAL OPTIONS DWG) C497 C676 C C
HORN SIGNAL 5
7200 WHT
C C
SJC HORN/BLINKER
LEFT SPEAKER
* * RADIO CONN A A

HANDLE LOCK (ACS ONLY) RIGHT BLINKER SIGNAL 4

6420 PNK
A A (SEE ADDITIONAL 1
7820 WHT
3
LEFT
SPEAKER (+)
*
OPTIONS DWG) 1
6520 PNK 7830 WHT LEFT
LEFT BLINKER SIGNAL 3 B B 2 4 SPEAKER (-) 2
L010
C279 3
FLOAT (ACS/AHC ONLY) HIGH FLOW 2460 BRN AIR RIDE SEAT
SOLENOID GROUND 26 RIGHT SPEAKER 1510 RNG/WHT
SHT12/E1 4
J2A GND
B
* 7810 WHT RIGHT
PWR
PWR

RIGHT POSTION SWITCH HIGH FLOW 2 6 SPEAKER (-)

SOLENOID 2210 BLK GND
SIG 7.5 OHM 12 V 7800 WHT RIGHT
SHT12/E1 5
PADDLE A 1 5 SPEAKER (+)
GND
6
C415 C278 1885 RNG/WHT
HIGH FLOW SOLENOID 4460 LGN C277
26 SHT12/E1 1
SIGNAL
J2B 2885 BLK
LEFT POSITION SWITCH
SHT12/D1 2
C408 GWY CTRLR
C676
MFR HARN CONN 1 C126
1460 RED/WHT
A SHT2/B1 (BLACK) HORN CONNECTOR TWO SPEED GROUND 26 2350 BRN
TRIGGER GND
7210 WHT 7210 WHT SIG 2
B 13 13 A A J1A TWO SPEED TRACK 2 SPEED
_
C412 SOLENOID (SEE ADDITIONAL
HORN 4350 LGN OPTIONS DWG)
SIG
1 5.1 OHM 12 V
2785 BLK GND +
SHT4/E8 B B TWO SPEED SIGNAL 26 C441

J1B

Wiring Schematic T870 S/N ASWT11947

S850 AJ9C11246 &&Above
Above WARNING PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 16 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427
CHG NOTICE DWN
MPS
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 16 / 17
7302615
Printable Version Click Here
611 of 1052
 C438
*SW7
RIDE CONTROL
AUX CTRLR
RIDE CONTROL SW AUTO 23
MFR HARN CONN 3 (DK GRAY)
3410 LBL
14 14
3410 LBL
1 2
2890 BLK
SHT4/E8 OPTIONS 2
* DLX CAB HARN 7301237 ONLY
SW7 SW7 (NOT IN STD CAB HARN 7303755)

3480 LBL
RIDE CONTROL RELAY SIG 7 RIDE CONTROL
RELAY - L
FUSE RELAY CENTER

1575 RNG/WHT
3415 LBL SP9 3425 LBL L1 SHT3/F1
RIDE CONTROL RELAY FEEDBACK 21 L4
3435 LBL 3445 LBL 2505 BLK
1 1 L5 L2 SHT4/C8
RIDE CONTROL RIDE CONTROL FRC1
COIL FRC1
COIL
2040 BLK
SP32 2020 BLK
2 2
C439 C440
2155 BLK
SHT4/G8

C428 * SW13
REVERSING FAN
MFR HARN CONN 2 (LT GRAY)
3475 LBL 3475 LBL
REVERSING FAN MANUAL SIG 16 7 7 3

2905 BLK 2970 BLK

SHT16/D3 1 2 SHT16/D3
3470 LBL 3470 LBL
REVERSING FAN AUTO SIG 29 8 8 6
1565 RNG/WHT
5 SHT3/D1
4
C443
2175 BRN
SW13 SW13
REVERSING FAN RETURN SIG 27 2
J2A

3485 LBL
REVERSING FAN SIG 25 1

2185 BRN
SHT4/D3 A
3455 LBL RIDE CONTROL
RIDE CONTROL PRESSURE SENSOR SIG 10 C
PRESSURE SENSOR
5105 YEL
RIDE CONTROL SENSOR 5V SUPPLY 24
J2B
B
C442
* SW8 C672
SIDELIGHT SIDELIGHT CONN
6710 PNK/WHT
1405 RED/WHT 1 1 1
SHT16/G3 2
2810 BLK
SHT16/D3 2 2
2860 BLK
6 SHT4/E8

SW8 SW8

Wiring Schematic T870 S/NWARNING

S850 AJ9C11246 &&Above
ASWT11947 Above PROPRIETARY NOTICE TOLERANCES: ECN 102539 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
SCPA Machine S/N B3BZ11142
B3BY11138 &through
AboveB3BY11299 7302615 (B)
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEM ELEC EXLF SCPA
S/NCOPYRIGHT
B47711001 through B47711399
C
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE
SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
UNLESS OTHERWISE SPECIFIED
X ± 13 MAT
Sheet 17 of 17
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
B
REV
SEE SHEET 1
DESCRIPTION
103427 MPS
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 17 / 17
7302615
Printable Version Click Here
612 of 1052
 LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
PARTIAL CONNECTOR
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
CONNECTOR C426 To Mainframe
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN SSL 7-PIN
CAN CONNECTOR D F C E A B G
Harness

MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL

HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN

9800
1160
9700
1710
9500
9600
2710
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
LIGHTS 6000 THROUGH 6999 PINK PNK
WIRE BREAK KEY "RUN" D 9800 PUR C705 J1 - 8-PIN

(TWO WIRE BREAKS UNSW POWER F 1160 RED/WHT 2720 H GROUND

OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT CAN SHIELD C 9710 PUR 9710 F CAN SHIELD
JOIN ONE WIRE) SW POWER E 1730 RNG 9 1720 B SW POWER ACD
ENGINE 8000 THROUGH 8999 TAN TAN 9 Machine
SHEET # CAN LOW B 9620 PUR 9610 E CAN LOW
Connector to
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR CAN HIGH A 9520 PUR 14 9510 D CAN HIGH Engine
GROUND G 2730 BLK 13 C OPEN Compartment
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT Connector 7-PIN A
C666 ATTACHMENT
OPEN
on Loader G OPEN
CONNECTOR
SSL 7-PIN Boom
CAN CONNECTOR J
BOOM-MOUNTED
N ACD CONNECTORS
KEY "RUN" D 9800 D SW POWER K 1740

UNSW POWER 2 1160 F

GROUND B 2740 C703 J2 - 10-PIN BLACK
E OUTPUT E 5100 5100 C E OUTPUT
CAN SHIELD C 9700 C F OUTPUT F 5350 5350 H F OUTPUT
SW POWER 1 1710 E G OUTPUT G 5400 5400 J G OUTPUT
H OUTPUT H 5050 5050 B H OUTPUT ACD
CAN LOW B 9600 A Output
C OUTPUT C 5300 5300 G C OUTPUT
CAN HIGH A 9500 B Connector to
D OUTPUT D 5150 5150 D D OUTPUT
Engine
GROUND 3 2700 G A OUTPUT A 5250 5250 F A OUTPUT Compartment
7-PIN M E
Connector M OUTPUT 5200 5200 B OUTPUT

on Loader C666 C426

ATTACHMENT
CONNECTOR
ID (K TO L) L
P
5910
12
5000 A
K
J OUTPUT

Boom ID (K TO P) 5510 5450 K OUTPUT

11
CONTROL HARNESS - 7175321 Connector
C506 14-PIN
ATTACHMENT
CONNECTOR
C704 J3 - 10-PIN GRAY

on Loader 5900 J ID #1

Boom 5500 A ID #2
B ID #3
ACD
C ID #4 Input
D ID #0 Connector to
C667 SW7 DELUXE ATTACHMENT E OPEN
Engine
Compartment
DOOR HARN C250 SENSOR SHOWN F OPEN
REAR CONTROL HARNESS - G OPEN
4 3630/LBL 1 SIG WITH DOOR OPEN C129 WIPER 6732730 H OPEN

5 1400/RED/WHT 2 PWR DOOR SENSOR A SWITCH K OPEN

TO CAB B
TO DLX CAB 6 1865/RNG/WHT 1 2
HARNESS
HARNESS 1 C 2820/BLK 3
3 4 5 7230/WHT T6 1
6 REAR
2 WIPER
MOTOR C667
7170531 SPECIAL APPS DOOR HARNESS DOOR HARN C250 SENSOR SHOWN
4 3630/LBL 1 SIG WITH DOOR OPEN
7180207 REAR WIPER HARNESS 5 1400/RED/WHT 2 PWR DOOR SENSOR
C251
6 7330/WHT C PARK
R2
CAB 1570/RNG/WHT
C667 750 OHM RESISTOR E
DOOR HARN C250 HARNESS
1W 5%
5 1400/RED/WHT 1 1400/RED/WHT 1 1850/RNG/WHT 3 7300/WHT A LOW
1 WIPER
1410/RED/WHT

2
3 7310/WHT 6 1860/RNG/WHT D SW PWR MOTOR
4 5
R1
300 OHM RESISTOR SW8
0.5W 5% C251 FRONT WIPER
SENSOR SHOWN SWITCH
4 3630/LBL 2 3630/LBL 3635/LBL 2 SIG WITH DOOR OPEN 2 2840/BLK B GND

2860/BLK 3 2860/BLK 1 GND DOOR SENSOR

6
7155024 DOOR HARNESS
7195485 DOOR SENSOR HARNESS
TO DLX
CAB HARNESS Printable Version Click Here
C251
7330/WHT C PARK WIRING SCHEMATIC
SW8 1570/RNG/WHT

1850/RNG/WHT
FRONT WIPER
SWITCH
E
(KIT AND OPTION HARNESS)
1 3 7300/WHT A LOW

3 7310/WHT
1
6
2
1860/RNG/WHT D SW PWR
WIPER
MOTOR ALL MODELS
4 5
2 2840/BLK 2850/BLK B GND Sheet 1 of 6
7171105 FORESTRY DOOR HARNESS
(PRINTED OCTOBER 2017)

Printed In U.S.A. 7195572 (E)

613 of 1052
 C425
C489-B B C427
TO
1 BRAKE
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE 1510/RNG MAINFRAME A 4200/LGN 1 SOLENOID
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE 2210/BLK 2 HARNESS C 2
2200/BLK 9.8 OHM
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED 12 V
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT C220 C489-A
C437 C428
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT A 1520/RNG 1 TO
1500/RNG 2 2360/BRN 2 GND TWO SPEED
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK C 2 MAINFRAME MAKEUP SOLENOID
2230/BLK 2220/BLK 1 4360/LGN 1 SIG
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN HARNESS 8.8 OHM 12V
B 6500/PNK
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN C441 C429
TO
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL C103-A C103-B 2 2350/BRN 2 GND TWO SPEED
MAINFRAME
LIGHTS 6000 THROUGH 6999 PINK PNK G 6501/PNK 6502/PNK G HARNESS 1 4350/LGN 1 SIG SOLENOID
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT 5.1 OHM 12 V
ENGINE 8000 THROUGH 8999 TAN TAN H 6200/PNK H
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR B 2600/BLK B
EXMF, LF: 7177692 2 SPD TRACK ADAPTER
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT D 6510/PNK D EXLF: 7190709 2 SPD TRACK ADAPTER
E 6410/PNK E
F F
7110/WHT
A 6310/PNK A
BACK-UP ALARM
C 7100/WHT C SWITCHES
C404
TO A 7100/WHT
MAINFRAME B 1720/RNG/WHT
7219294 - HARNESS NEUTRAL LIGHT HARNESS
LEGEND
7175017 BACK-UP ALARM HARNESS
PARTIAL CONNECTOR

C362 C414
A 4440/LGN 1 SIG
REAR BASE (M) C411 TO
B 2440/BLK 2 GND 7.5 OHM 12V MAINFRAME
CONNECTOR WHITE TIE STRAP A C E B D HARNESS
C413 (5 WAY LH)
C 4430/LGN 1 SIG

6000/PNK
REAR ROD (F)
D 2430/BLK 2 GND 7.5 OHM 12V
WIRE BREAK C497 6510/PNK
TO BROWN TIE STRAP
(TWO WIRE BREAKS
MAINFRAME
C416 B 6415/PNK 2780/BLK
JOIN ONE WIRE)
HARNESS E 4450/LGN 1 SIG REAR ROD LOCK 86 85
SHEET # 6410/PNK
F 2450/BLK 2 GND 7.5 OHM 30
87
12 V TO A 6515/PNK 2790/BLK
YELLOW TIE STRAP MAINFRAME
C417 86 85
G 4480/LGN 1 HARNESS
SIG 30 6010/PNK 6020/PNK
REAR BASE LOCK 87
H 2480/BLK 2 GND
9.8 OHM
GREEN TIE STRAP 12 V C 7200/WHT 2770/BLK
86 85
7173271 REAR AUX HARNESS C412 30
TO 87
B 2785/BLK
MAINFRAME
HARNESS A 1420/RED/WHT
(2 WAY LH)

TO C489-1 C489-2
ADDITIONAL
MAINFRAME B B
2720/BLK 2740/BLK ACCESSORY
HARNESS
C414 A 1720/RNG A POWER
(ACCESSORY
4440/LGN 1 SIG CONNECTOR
REAR BASE POWER)
AUX CTRLR J2B PIN 5
2440/BRN 2 GND 7.5 OHM 12V
AUX CTRLR J2A PIN 2 7151940 SJC/AWS/SCPA HRN/BLINKER HARNESS
WHITE TIE STRAP
C413
AUX CTRLR 4430/LGN 1 SIG
J2B PIN 7 REAR ROD
2430/BRN 2 GND 7.5 OHM 12V Printable Version Click Here
AUX CTRLR J2A PIN 10
BROWN TIE STRAP

TO C489-1
J2B PIN 4
4450/LGN
C416
1 SIG
WIRING SCHEMATIC
MAINFRAME REAR ROD LOCK
(KIT AND OPTION HARNESS)
B 2720/BLK 2450/BLK 2 GND
HARNESS 7.5 OHM
(ACCESSORY A 1780/RNG/WHT 2725/BLK YELLOW TIE STRAP 12 V
POWER) C417
ADDITIONAL
C489-2
A
4480/LGN 1 SIG
REAR BASE LOCK
ALL MODELS
ACCESSORY 2480/BLK 2 GND
POWER
CONNECTOR
B J2B PIN 6
GREEN TIE STRAP
9.8 OHM
12 V Sheet 2 of 6
7191339 or 7201414 REAR AUX HARNESS (PRINTED OCTOBER 2017)

Printed In U.S.A. 7195572 (E)

614 of 1052
 LEGEND
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE PARTIAL CONNECTOR
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN CONNECTOR
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN C129
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL CAB ACCESSORY
LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK POWER CONN
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS A 1410/RED/WHT 1200/RED/WHT
JOIN ONE WIRE)
ENGINE 8000 THROUGH 8999 TAN TAN
SHEET # 1430/RED/WHT X T3
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR B FLASHER CONN
TO STANDARD SW2
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
CAB HARNESS L
BEACON
SWITCH
C 2780/BLK
2725/BLK 6
SW3 5
4
4 WAY FLASHER 1 2
SWITCH
3
6570/PNK 1
C670 C609 2 2780/BLK
3 C670
E 6700/PNK 1 C669 (PINS 3 & 6 4
STD CAB: STROBE 5 2850/BLK 6700/PNK E
D 2780/BLK 2775/BLK 2 INTERNALLY
TO ACC HARNESS BEACON 1 6440/PNK RIGHT 6 D
C INSULATED) 2420/BLK
FLASHER TO EXTERIOR
A 2785/BLK 2 2785/BLK 2795/BLK C
DLX CAB: LIGHT CAB HARNESS
TO DLX CAB HARNESS F 6440/PNK 2790/BLK A
B 3 LEFT 6440/PNK F
6540/PNK 6540/PNK
FLASHER 6540/PNK B
7169130 ACC HARNESS
LIGHT
(STD CAB HARNESS ONLY)
6718872 EXTERIOR CAB HARNESS
7169753 4 WAY FLASHER HARNESS

C800
C667
6340/PNK A 6340/PNK REGISTRATION DOOR HARN C250 SENSOR SHOWN
2670/BLK B 2670/BLK (LICENSE PLATE) WITH DOOR OPEN
4 3620/LBL 1 SIG
LAMP
5 1400/RED/WHT 2 PWR DOOR SENSOR
7153090 HARNESS LICENSE LIGHT
6 C251
TO EURO 3 C PARK
7310/WHT
TAILGATE C603 HT
HARNESS Taillight Right CAB 3 30/W
E 1 1570 7
7104670 HARNESS 5
6 A LOW
C103 F 1850/RNG/WHT
D A 3 HT
6510/PNK 6510/PNK BLU
1 7 300/W E HIGH WIPER
C407-A C407-B 6610/PNK C RED 2814 MOTOR
2 2840/BLK 4
2 7305/WHT
H 6200/PNK 6320/PNK A A 6430/PNK B YEL
B 2600/BLK 2610/BLK D BLK 1860/RNG/WHT D SW PWR
BREAK CONNECTION INTERMITTENT WIPER
FOR ROADLIGHT KIT 2620/BLK SWITCH
-
2842/BLK B GND
6210/PNK +

Backup Alarm
7231771 INTERMITTENT WIPER DOOR HARNESS
6660294
NOTE: SPLICE ADDED BEFORE
WITH ROADLIGHT KIT: C 2650/BLK CONNECTOR INSTEAD OF AT PIN.
7100/WHT
TO ROADLIGHT KIT + -
C602
HARNESS G 6600/PNK Taillight Left
E Taillight Left Printable Version Click Here
F 7104671
7104671
WITHOUT ROADLIGHT
KIT: TO MAINFRAME
E 6410/PNK 6410/PNK
6620/PNK
A
C
BLU
RED
WIRING SCHEMATIC
(KIT AND OPTION HARNESS)
HARNESS 6330/PNK B YEL

6210/PNK
F D BLK
2640/BLK

2630/BLK
6210/PNK
-
-
ALL MODELS
+
6310/PNK 6250/PNK
Sheet 3 of 6
+
A 6310/PNK 6310/PNK
SP24
7217483 - HARNESS EUR TAILGATE
7175287 - HARNESS EUR TAILGATE (HARNESS SAME AS 7175287
EXCEPT AS SHOWN ABOVE) (PRINTED OCTOBER 2017)

Printed In U.S.A. 7195572 (E)

615 of 1052
 WIRE CATEGORIES FOR COLORS AND NUMBER RANGE LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE PARTIAL CONNECTOR
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT F 1
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK E 3
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN CONNECTOR
7210/WHT A 6330/WHT 2
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN 2310/BLK B 2120/BLK 6
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL C 5 Front Turn Light
7230/WHT 6120/LGN
LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
7270/WHT D 6340/RED 4
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS
ENGINE 8000 THROUGH 8999 TAN TAN JOIN ONE WIRE)
Position Light
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR SHEET #
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT

C407-B
TO EURO
6430/PNK
TAILGATE F F
HARNESS Relay1
6420/PNK A 7210/WHT E
Right Side Lights
87 6410/PNK 6440/PNK D 7250/WHT 7260/WHT B
1020/RED 1410/RED/WHT
6510/PNK E C Brake Light
10.0 Amps 30 7200/WHT 7200/WHT
6400/PNK 6220/PNK C 7220/WHT 7240/WHT A
85 86 2020/BLK
2110/BLK B 2300/BLK 2320/BLK D Rear Turn Light
T01
Relay2
Left Side Lights
87 6310/PNK
1010/RED 1400/RED/WHT
10.0 Amps 30
T02
6300/PNK 85 86 2030/BLK

2120/BLK B 2300/BLK E
ADDITIONAL
1510/RNG A
ACCESSORY 6330/PNK A 7210/WHT F
2210/BLK B POWER
6120/PNK C 7220/WHT 7240/WHT A
CONNECTOR
6340/PNK D 7250/WHT 7260/WHT B Rear Position Light
1730/RNG A 1520/RNG 1500/RNG A 6520/PNK E 7200/WHT C
C 2200/BLK B HARNESS F D Brake Light
2730/BLK 2230/BLK 2320/BLK
87
6600/PNK B 6500/PNK
30
87A
85 86

TO
SJC/AWS/SCPA A 6330/WHT 2
4210/LGN 1 7210/WHT
CONTROLS HARNESS
(1 PIN CONN) 7270/WHT D 6340/RED 4 Position Light

7175581 - SJC BRAKE HARNESS

E 3
(ONLY FOR SJC OPTION) 7230/WHT C 6120/LGN 5
2310/BLK B 2120/BLK 6
F 1

H 6010/PNK 6320/PNK H

6530/PNK G
B 2000/BLK 2010/BLK B
D
E
6210/PNK
6110/PNK
6230/PNK
6130/PNK
D
E HARNESS WIRING SCHEMATIC Printable Version Click Here
HARNESS F
G
F
(KIT AND OPTION HARNESS)
A 6000/PNK 6000/PNK A ALL MODELS
C 7100/WHT 7100/WHT C
Sheet 4 of 6
(PRINTED OCTOBER 2017)

Printed In U.S.A. 7195572 (E)

616 of 1052
 LEGEND
PARTIAL CONNECTOR

** HARNESS STVB 04
1
2
CONNECTOR
** HARNESS HEIGHT ADJUSTMENT
STVB A
STVB 02 STVB 92 L4/RD
WIRE BREAK
1 L1/BK
COMPRESSOR (TWO WIRE BREAKS
2 (SUSPENSION) JOIN ONE WIRE)
STVB B
3 SHEET #
S1
(MOMENTARY)
L2/RD 1 4
2
C277
HEATING MAT SEAT
1 L6/BK L3/RD YEL

2
** HARNESS STVB 03 STVB xx
3

L5/RD
1
HARNESS 4 L1/RD 2
5 L3/BK L4/BK

L12/BLK
60°C / 50°C

L13/BRN
6 L2/VT
BRN

STVB H2 HEATING SWITCH

L10/RED
S2

STVB 03 STVB H1 STVB H3

1
L7/BK 2

L14/BRN
YEL HEATING MAT BACK

STVB H5 STVB xx
L11/BLK 1
2
60°C / 50°C

BRN

7308952 HEATED SEAT Printable Version Click Here

WIRING SCHEMATIC
(KIT AND OPTION HARNESS)
ALL MODELS
Sheet 5 of 6
(PRINTED OCTOBER 2017)
Printed In U.S.A. 7195572 (E)
617 of 1052
 WIRE CATEGORIES FOR COLORS AND NUMBER RANGE LEGEND
GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE PARTIAL CONNECTOR
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
BATTERY GROUND 2000 THROUGH 2999 BLACK BLK
CONTROLLER GROUND/RETURN 2000 THROUGH 2999 BROWN BRN CONNECTOR
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
CONTROLLER SUPPLY 5000 THROUGH 5999 YELLOW YEL
LIGHTS 6000 THROUGH 6999 PINK PNK WIRE BREAK
OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT (TWO WIRE BREAKS
ENGINE 8000 THROUGH 8999 TAN TAN JOIN ONE WIRE)
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR SHEET #
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT

C001
CALAMP TELEMATICS CONN
C678
1
MACHINE CONN
2
3 9502/PUR/WHT/18 4 CAN HI
4 9602/PUR/18 3
CAN LO
5
6
7
8
9
10 1167/RED/WHT/18 1
UNSWITCHED POWER 7335305 & 7335295 NON-TELEMATIC JUMPER
11 2712/BLK/18 2
CAN GROUND
12

Printable Version Click Here

7300058 CALAMP ADP TELEMATICS HARNESS
WIRING SCHEMATIC
(KIT AND OPTION HARNESS)
ALL MODELS
Sheet 6 of 6
(PRINTED OCTOBER 2017)

Printed In U.S.A. 7195572 (E)

618 of 1052
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
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
+ when released.)
POSITIVE ELECTRICAL CIRCUIT -
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
electrical current to supply voltage to on switch application.
G 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.

619 of 1052 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 - Key - Multi position switch 0.5 ohm A the solenoid coils are listed next to
B
to activate various start functions at the component [if available]). The pull
ST different positions. solenoid is energized for a short time.

START
HORN - Audible alarm. Sound is
RUN
OFF
activated manually by a switch.

BUZZER - Audible alarm. Sounds at a

1
SWITCH - Light - Multi position switch 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

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 MOTOR - Wiper - Single or multi
GRD
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

3700 3710 SPLICE (•) - Used to show when

3110
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.)

620 of 1052 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
-
B pressure. (Sender voltage rating is
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
500-3000 ohm
ohm rating is listed to show ohm at
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.)

FUEL SENDER - Provides a variable

B
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.

621 of 1052 60-10-3 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Deluxe Cab Harness Connectors

NA13708

622 of 1052 60-10-4 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

SCPA Mainframe Harness Connectors

NA13711

623 of 1052 60-10-5 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

SJC Mainframe Harness Connectors

NA13710

624 of 1052 60-10-6 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Engine Harness Connectors

NA9665

625 of 1052 60-10-7 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Description

Figure 60-10-1

P100958A P121167

The loader has a 12 volt, negative ground, alternator

charging system.

The electrical system is protected by fuses located in the

operator cab and a 100 ampere master fuse (Inset)
[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.

626 of 1052 60-10-8 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

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.
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 60-10-5], [Figure
60-10-6] and [Figure 60-10-7].

627 of 1052 60-10-9 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 60-10-4

Fuse And Relay Location / Identification 1

Figure 60-10-2

1
P109659
1
Line up the clips on the back of the fuse panel cover with
P100414
the slots (Item 1) [Figure 60-10-4] in the fuse panel and
push the cover into position when finished.

The fuse / relay panel is located behind an access panel Line up the clips on the back of the access panel with the
near the left foot pedal / footrest. Pull the panel at each slots provided and push the panel into position [Figure
end (Item 1) [Figure 60-10-2] to remove. 60-10-2]. A locating pin prevents the panel from being
installed upside down.
Figure 60-10-3
A table is provided with details on amperage ratings and
the circuits affected by each fuse and relay. [Figure 60-
10-5 on Page 60-10-11] or [Figure 60-10-6 on Page 60-
10-12] or[Figure 60-10-7 on Page 60-10-13]

1
P107513B

The electrical system is protected from overload by fuses

located behind the fuse panel cover (Item 1) [Figure 60-
10-3]. Remove the fuse panel cover by pulling at each
end.

A decal located on the fuse panel cover indicates fuse

and relay location and fuse amperage ratings.

628 of 1052 60-10-10 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Fuse And Relay Location / Identification (Cont’d)

Figure 60-10-5

NA3313

NA3313

The table below is for earlier models with decal part number 7251372. Fuse location and amperage ratings are shown
in the table below and on the decal [Figure 60-10-5]. Relays are identified by the letter “R” in the AMP column.

ITEM ICON DESCRIPTION AMP ITEM ICON DESCRIPTION AMP ITEM ICON DESCRIPTION AMP

Cab Switched
F1 Rear Lights 15 F14 5 A Switched Power R
Power

F2 Front Lights 20 F15 ACS Controller 25 B Heater / HVAC R

F3 Traction 30 F16 Engine Controller 25 C Fan R

Drive Controller
F4 Heater / HVAC 25 F17 25 D Traction R
Back-up Alarm

Switched Power
F5 25 F18 Attachments 25 E Rear Lights R
Back-up Alarm

F6 Wiper / Washer 25 F19 Not Used -- F Not Used --

F7 Switched Power 25 F20 Engine Controller 5 G Engine Controller R

Cab Switched
F8 25 F21 Engine Controller 15 H Not Used --
Power

Accessories and
F9 Not Used -- F22 25 J Front Lights R
Front Horn

F10 Fan 30 F23 Alternator 15 K Front Lights R

Cab Accessories
F11 Bobcat Controller 25 F24 25 L Not Used --
Power Port

F12 Bucket Position 15 F25 Hose 10 M Starter R

Auxiliary
F13 25 F26 Dosing Controller 15
Controller

629 of 1052 60-10-11 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Fuse And Relay Location / Identification (Cont’d)

Figure 60-10-6

NA3314

The table below is for later models with decal part number 7280029. Fuse location and amperage ratings are shown
in the table below and on the decal [Figure 60-10-6]. Relays are identified by the letter “R” in the AMP column.

ITEM ICON DESCRIPTION AMP ITEM ICON DESCRIPTION AMP ITEM ICON DESCRIPTION AMP

Cab Switched
F1 Rear Lights 15 F14 5 A Switched Power R
Power

F2 Front Lights 20 F15 ACS Controller 25 B Heater / HVAC R

F3 Traction 30 F16 Engine Controller 25 C Fan R

Drive Controller
F4 Heater / HVAC 25 F17 25 D Traction R
Back-up Alarm

Switched Power
F5 25 F18 Attachments 25 E Rear Lights R
Back-up Alarm

F6 Wiper / Washer 25 F19 Not Used -- F Not Used --

F7 Switched Power 25 F20 Engine Controller 5 G Engine Controller R

Cab Switched
F8 25 F21 Engine Controller 15 H Not Used --
Power

Accessories and
F9 Not Used -- F22 25 J Not Used --
Front Horn

F10 Fan 30 F23 Alternator 15 K Not Used --

Cab Accessories
F11 Bobcat Controller 25 F24 25 L Not Used --
Power Port

F12 Bucket Position 15 F25 Hose 10 M Starter R

Auxiliary
F13 25 F26 Dosing Controller 15
Controller

630 of 1052 60-10-12 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Fuse And Relay Location / Identification (Cont’d)

Figure 60-10-7

NA3328

The table below is for later models with decal part number 7300261. Fuse 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.

ITEM ICON DESCRIPTION AMP ITEM ICON DESCRIPTION AMP ITEM ICON DESCRIPTION AMP

Cab Switched
F1 Rear Lights 15 F14 5 A Switched Power R
Power

F2 Front Lights 20 F15 ACS Controller 25 B Heater / HVAC R

F3 Traction 30 F16 Engine Controller 25 C Fan R

Drive Controller
F4 Heater / HVAC 25 F17 25 D Traction R
Back-up Alarm

Switched Power
F5 25 F18 Attachments 25 E Rear Lights R
Back-up Alarm

F6 Wiper / Washer 25 F19 Not Used -- F Not Used --

F7 Switched Power 25 F20 Engine Controller 5 G Engine Controller R

Cab Switched
F8 25 F21 Engine Controller 15 H Not Used --
Power

Accessories and
F9 Not Used -- F22 25 J Not Used --
Front Horn

F10 Fan 30 F23 Alternator 15 K Not Used --

Cab Accessories Automatic Ride

F11 Bobcat Controller 25 F24 25 L R
Power Port Control

F12 Bucket Position 15 F25 Hose 10 M Starter R

Auxiliary
F13 25 F26 Dosing Controller 15
Controller

631 of 1052 60-10-13 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 60-10-10

Fuse And Relay Location / Identification (Cont’d)

Figure 60-10-8

P121159

(Earlier models with decal part number 7251372) -

1 Four additional relays (Item 1) [Figure 60-10-10] for the
P121166A
DEF / AdBlue® tank heater system are located under the
operator cab on the left side of the loader. Stop the
Two 15 ampere inline fuses (Item 1) [Figure 60-10-8] for engine and raise the operator cab to access the relays.
the rear door fans are located on the inside of the rear (See Raising on Page 10-30-1.)
door.
Figure 60-10-11
Figure 60-10-9

P121159A
P100958B P121621A

(Later models with decal part number 7280029 or

The air intake heater is protected by a 150 ampere inline 7300261) - Six additional relays are located under the
fuse (Inset) located just above the battery inside a two- operator cab on the left side of the loader. Four relays
piece rubber boot (Item 1) [Figure 60-10-9]. Slide the (Item 1) are for the DEF / AdBlue® tank heater system.
rubber boot apart to access the fuse holder. Two relays (Item 2) [Figure 60-10-11] are for the front
lights. Stop the engine and raise the operator cab to
access the relays. (See Raising on Page 10-30-1.)

632 of 1052 60-10-14 T870 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Solenoid Testing

Figure 60-10-12

P9175

Use a test meter to measure coil resistance [Figure 60-

10-12]. Coil wires do not have polarity. Correct resistance
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.

633 of 1052 60-10-15 T870 Service Manual

634 of 1052 60-10-16 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
and wash eye with clean, cool water for at least 15 P100959 P100960
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.

Stop the engine and open the rear door. Connect the negative (-) cable last to prevent sparks.

When removing the battery from the loader, do not touch Connect and tighten the battery cables.
any metal parts with the battery terminals.
Install and tighten the battery hold-down.
Figure 60-20-1
Put Bobcat Battery Saver or grease on the battery
terminals and cable ends to prevent corrosion.
2
Close the rear door.

1
WARNING
BATTERY GAS CAN EXPLODE AND CAUSE
3 SERIOUS INJURY OR DEATH
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
4
P121168 make final connection (negative) at machine frame.

Do not jump start or charge a frozen or damaged

Disconnect the negative (-) cable (Item 1) [Figure 60-20- battery. Warm battery to 16°C (60°F) before
1]. connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
Remove the battery hold-down clamp (Item 2) [Figure lean over battery while boosting, testing or charging.
60-20-1]. W-2066-0910

Disconnect the positive (+) cable (Item 3) [Figure 60-20-

1] from the battery.

Remove the battery wrap (Item 4) [Figure 60-20-1] and

the battery from the loader.

635 of 1052 60-20-1 T870 Service Manual

BATTERY (CONT’D)

Servicing

See the SERVICE SCHEDULE for the correct service

interval. (See SERVICE SCHEDULE on Page 10-70-1.)

Figure 60-20-3

P100959 P100960

The battery cables must be clean [Figure 60-20-3] and

tight.

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.

Check electrolyte level in the battery. Add distilled water

as needed.

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

636 of 1052 60-20-2 T870 Service Manual

BATTERY (CONT’D) Connect the end of the second cable (Item 3) [Figure 60-
20-4] to the negative (-) terminal of the booster battery.
Using A Booster Battery (Jump Starting) Connect the other end of the same cable (Item 4) [Figure
60-20-4] to the engine.
If the engine will not start without using a booster battery,
BE CAREFUL! There must be one person in the Keep cables away from moving parts. Start the engine.
operator’s seat and one person to connect and
disconnect the battery cables. After the engine has started, remove the negative (-)
cable (Item 4) [Figure 60-20-4] first. Remove the cable
The key switch must be in the STOP position. The from the positive terminal (Item 2) [Figure 60-20-4].
booster battery must be 12 volt.
Remove the cables from the booster battery.

Close the rear door.

WARNING
BATTERY GAS CAN EXPLODE AND CAUSE
SERIOUS INJURY OR DEATH
Keep arcs, sparks, flames and lighted tobacco away
IMPORTANT
from batteries. When jumping from booster battery
Damage to the alternator can occur if:
make final connection (negative) at machine frame.
• Engine is operated with battery cables
disconnected.
Do not jump start or charge a frozen or damaged
• Battery cables are connected when using a fast
battery. Warm battery to 16°C (60°F) before
charger or when welding on the loader. (Remove
connecting to a charger. Unplug charger before
both cables from the battery.)
connecting or disconnecting cables to battery. Never
• Extra battery cables (booster cables) are
lean over battery while boosting, testing or charging.
W-2066-0910
connected wrong.
I-2023-1285

Open the rear door.

Figure 60-20-4

3 1

P121189A

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 engine starter.

637 of 1052 60-20-3 T870 Service Manual

638 of 1052 60-20-4 T870 Service Manual
ALTERNATOR Figure 60-30-2

Belt Adjustment

The alternator belt is a special maintenance free type 1

that is pretensioned over the pulleys. This belt eliminates
the need for a tensioning device and does not require
periodic adjustment.

Belt Replacement

If machine is equipped with air conditioning. (See

Compressor Drive Belt Replacement on Page 80-20-2.)
2
Stop the engine and open the rear door.
P121089A
Figure 60-30-1

Remove the bottom alternator mounting bolt (Item 2).

Loosen the top alternator mounting bolt (Item 1) [Figure
60-30-2].

Move the alternator toward the engine as far as it will go

1 2 and remove the belt from the pulleys.

Inspect the pulleys for wear.

Install new belt.

Figure 60-30-3

P121090A

Remove the alternator belt shield mounting nuts and 1

bolts (Item 1) [Figure 60-30-1].

Remove the alternator belt shield (Item 2) [Figure 60-30-

1].

P121088A

Use a prybar (Item 1) [Figure 60-30-3] in the location

shown to move the alternator until the bottom alternator
mounting bolt (Item 2) [Figure 60-30-2] can be installed.

Tighten the top alternator mounting bolt and the bottom

alternator mounting bolt [Figure 60-30-2].

Install the alternator belt shield, mounting bolts, and nuts

[Figure 60-30-1].

Close the rear door.

639 of 1052 60-30-1 T870 Service Manual

ALTERNATOR (CONT’D) Figure 60-30-4

Charging System Inspection

1
WARNING
1
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
P115846
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
of water or milk! DO NOT induce vomiting. Get Check the condition and tension of the alternator belt.
prompt medical attention. (See Belt Adjustment on Page 60-30-1.) Replace belt if
W-2065-0807 worn or deteriorated.

Inspect the alternator wiring harness connectors (Item 1)

[Figure 60-30-4] at alternator. Harness connectors must

WARNING be clean and tight.

Check the fuse for the alternator in the fuse panel. If fuse
BATTERY GAS CAN EXPLODE AND CAUSE is burned, find the cause and repair / replace. If fuse is in
SERIOUS INJURY OR DEATH doubt, remove it and check for continuity.
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery Check the electrolyte level in the battery. Add distilled
make final connection (negative) at machine frame. water as needed. (Does not apply to maintenance free
batteries.)
Do not jump start or charge a frozen or damaged
battery. Warm battery to 16°C (60°F) before Verify the charge of the battery. Make sure battery is fully
connecting to a charger. Unplug charger before charged.
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging. Disconnect the battery cables (negative first, then
W-2066-0910 positive). Inspect the cable clamps and battery posts for
corrosion. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate and water solution. Put
grease on the cable ends and battery terminals to
prevent corrosion. Reconnect the cable to the positive

IMPORTANT terminal.

Damage to the alternator can occur if:

• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

640 of 1052 60-30-2 T870 Service Manual

ALTERNATOR (CONT’D) Low Voltage Testing

Alternator Voltage Testing Figure 60-30-6

Figure 60-30-5

P115846

P115844
Turn engine OFF and remove the connector (Item 1)
[Figure 60-30-6] from the alternator.
Open rear door.
Turn the Remote Start Tool key to the ON position.
Connect the Remote Start Tool. (See REMOTE START
TOOL KIT - MEL1563 on Page 10-60-1.) or (See Figure 60-30-7
REMOTE START TOOL (SERVICE TOOL) KIT -
7217666 on Page 10-61-1.)

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).

If the voltage is higher that 14.7 volts, proceed to the 1 2

following high voltage test.

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 P115847
volts, proceed with the following low voltage test.

Check the voltage across the connector (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.

641 of 1052 60-30-3 T870 Service Manual

ALTERNATOR (CONT’D)

High Voltage Testing

Figure 60-30-8

P115846

Turn engine OFF and remove the B+ connector (Item 1)

[Figure 60-30-8] from the alternator.

Figure 60-30-9

2
1

P121222

Check the continuity between the B+ connector (Item 1)

[Figure 60-30-9] and the positive (+) terminal on the
battery or starter terminal (Item 2) [Figure 60-30-9].
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.

642 of 1052 60-30-4 T870 Service Manual

ALTERNATOR (CONT’D) Figure 60-30-11

Removal And Installation

IMPORTANT
Damage to the alternator can occur if: 2
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.) 1
• Extra battery cables (booster cables) are
P121090A
connected wrong.
I-2023-1285
Remove the nuts and bolts (Item 1) and the shield (Item
All Loaders 2) [Figure 60-30-11].

Disconnect the negative (-) cable from the battery. Non HVAC Equipped Loaders

Figure 60-30-10 Figure 60-30-12

1 2

3
1

P115846 P121089A

Disconnect the red wire (Item 1) [Figure 60-30-10] from Remove the bolt / ground cable (Item 1) [Figure 60-30-
the alternator which comes from the battery. 12].

Disconnect the wiring (Item 2) [Figure 60-30-10] from Remove the top alternator mounting bolt (Item 2). Loosen
the alternator. the bottom alternator mounting bolt (Item 3) [Figure 60-
30-12]. Move the alternator toward the engine fully and
remove the belt from the pulleys.

Remove the bottom alternator mounting bolt (Item 3)

[Figure 60-30-12].

Inspect the belt and pulleys for wear.

Remove the belt and alternator from the loader.

643 of 1052 60-30-5 T870 Service Manual

ALTERNATOR (CONT’D) Figure 60-30-15

Removal And Installation (Cont’d)

HVAC Equipped Loaders

Figure 60-30-13

2
P121079

1 Insert breaker bar into the hole provided in the idler

pulley (Item 1) [Figure 60-30-15] and push down to
release belt tension. Remove the belt from the pulleys.
P121903
Figure 60-30-16

Disconnect the water in fuel sensor (Item 1) and loosen

the fuel filter clamps (Item 2)[Figure 60-30-13].

Remove the fuel filter assembly from the clamps and

move clear of the air conditioning compressor belt shield.

Figure 60-30-14

1
2
P121089B

Remove the bolt / ground cable (Item 1) [Figure 60-30-

16].

P121080

Remove the air conditioning compressor belt shield

mounting bolts and nut (Item 2) [Figure 60-30-14].

Remove the air conditioning compressor belt shield (Item

1) [Figure 60-30-14].

644 of 1052 60-30-6 T870 Service Manual

ALTERNATOR (CONT’D)

Removal And Installation (Cont’d)

HVAC Equipped Loaders (Cont’d)

Figure 60-30-17

2
P121279

Remove the top alternator mounting bolt (Item 1) and the

bottom alternator mounting bolt (Item 2) [Figure 60-30-
17].

Remove the alternator from the loader.

Inspect the belt and pulleys for wear.

645 of 1052 60-30-7 T870 Service Manual

646 of 1052 60-30-8 T870 Service Manual
STARTER Removal And Installation

Testing 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. Figure 60-40-3

The cable connections on the battery must be clean and
tight. 2

Figure 60-40-1

Bat 1
S
M 1

Cranking
Motor P115850

Disconnect the wires and positive (+) cable (Item 1)

[Figure 60-40-3] from the starter solenoid.
A-1992

Installation: Tighten the nut to 14,7 - 16,7 N•m (10.8 -

12.3 ft-lb) torque.
Connect a jumper wire between S terminal and BAT
terminal [Figure 60-40-1].
Remove the three mounting bolts (Item 3) [Figure 60-40-
If the starter turns but does not turn the engine, the 3].
starter drive has a defect.
Remove the starter from the engine.
Figure 60-40-2

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.

647 of 1052 60-40-1 T870 Service Manual

STARTER (CONT’D)

Parts Identification

1. Starter 12 13. Washer

2. O-ring 14. Nut
3. Bracket 15. Shaft
4. Snap Ring 16. Ball
5. Stop 17. Armature
6. Gear 14 18. Bearing
13
7. Spring 19. Boot
8. Holder 11 20. Yoke
9. Lever 21. Holder
10. Plate 3
11. Lever 8 10
12. Switch 7
7
2
1 9
17

3
2 18
7
6
6 16
4 5

15

4
1
13
6
1
15
2

19

3 3

2 21

20

B-19824

648 of 1052 60-40-2 T870 Service Manual

INSTRUMENT PANELS

Left Panel

Figure 60-50-1

2 3 12
13

1 7
4 14 18

6 8 9 10 11 16
17
5 15

19 22
20 21

23 24

25

P-90726K

The left panel [Figure 60-50-1] is the same for all machines regardless of options and accessories.

ITEM DESCRIPTION FUNCTION / OPERATION

1 ENGINE TEMPERATURE GAUGE Shows the engine coolant temperature.
2 LEFT TURN SIGNAL (Option) Indicates left turn 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 is on when the seat bar is UP.
10 LIFT AND TILT VALVE The light is on when the lift and tilt functions cannot be operated.
11 PARKING BRAKE The light is on when the loader cannot be driven.

649 of 1052 60-50-1 T870 Service Manual

INSTRUMENT PANELS (CONT’D)

Left Panel (Cont’d)

ITEM DESCRIPTION FUNCTION / OPERATION

12 RIGHT TURN SIGNAL (Option) Indicates right turn signals are ON.
DIESEL EXHAUST FLUID (DEF) / Diesel exhaust fluid (DEF) / AdBlue® level low. (See DIESEL EXHAUST FLUID
13
AdBlue® MALFUNCTION (DEF) / ADBLUE® SYSTEM in this manual.)
Instructs operator to fasten shoulder belt when operating in high range. Remains lit
14 SHOULDER BELT
while in high range.
HYDRAULIC SYSTEM
15 Hydraulic system malfunction or failure. (See Service Codes*)
MALFUNCTION
16 FUEL Fuel level low or sensor error.
DIESEL EXHAUST FLUID (DEF) / Shows the amount of diesel exhaust fluid (DEF) / AdBlue® in the tank. (See
17
AdBlue® LEVEL SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM in this manual.)
18 FUEL GAUGE Shows the amount of fuel in the tank.
Press once for REAR taillights. (Right green LED will light.) Press a second time to
turn FRONT and REAR work lights ON. REAR taillights will turn OFF. (Left green
LIGHTS without road option
LED will light.) Press a third time to turn all lights off. (Left and right green LEDs will
be off.)
Press once for FRONT boom light, license plate light and REAR taillights. (Right
19
green LED will light.) Press a second time to turn FRONT and REAR work lights
LIGHTS with road option ON. FRONT boom light, license plate light and REAR taillights will turn OFF. (Left
green LED will light.) Press a third time to turn all lights off. (Left and right green
LEDs will be off.)
Press and hold 5 seconds to show software version in display screen.
Press once to engage auto idle. (Left green LED lights.) Press a second time to
AUTO IDLE
disengage. (See AUTO IDLE in this manual.)
20
Move cursor to the left inside the DISPLAY SCREEN when using certain
INFORMATION button menus.
AUXILIARY HYDRAULICS without Press once to activate the auxiliary hydraulic system. (Left green LED lights.) Press
high-flow option a second time to deactivate the system.
Press once to activate the auxiliary hydraulic system. (Left green LED lights.) Press
AUXILIARY HYDRAULICS with a second time to engage the HIGH-FLOW auxiliary hydraulics. (Left and right green
21
high-flow option LEDs light.) Press a third time to deactivate auxiliary hydraulics. (Left and right
green LEDs off.)
Move cursor to the right inside the DISPLAY SCREEN when using certain
INFORMATION button menus.
Cycles through (after each button press):
• Hourmeter (On startup)
• Engine rpm
• Battery voltage
22 INFORMATION
• Drive response menu
• Steering drift compensation menu
• Maintenance clock
• Service codes*
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 levers or joystick(s) to move the
23 TRACTION LOCK OVERRIDE
loader forward or backward when using the backhoe attachment. (See TRACTION
LOCK OVERRIDE in this manual.) Press a second time to lock the brakes.
Press to activate the BICS™ when the seat bar is down and operator is seated in
24 PRESS TO OPERATE LOADER
operating position. Button will light.
PARKING BRAKE (Standard on all Press the top to engage the Parking Brake. Press the bottom to disengage. (See
25
loaders) PARKING BRAKE in this manual.)

* This manual contains a table with Service Code descriptions. (See DIAGNOSTIC SERVICE CODES on Page 60-100-1.)

650 of 1052 60-50-2 T870 Service Manual

INSTRUMENT PANELS (CONT’D)

Display Screen

The display screen can display the following information:

• Operating hours
• Engine rpm
• Battery voltage
• Drive response setting
• Steering drift compensation setting
• Maintenance clock countdown
• Service codes
• Engine preheat countdown
• Speed management setting
• Lift and tilt compensation setting

Figure 60-50-2

3 4 5 6 7
NA3071

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 RPM

6. Battery / Charging Voltage

7. Service

651 of 1052 60-50-3 T870 Service Manual

INSTRUMENT PANELS (CONT’D) The switch location (Item 2) [Figure 60-50-3] can have
different functions depending on machine configuration.
Right Panel (Standard Key Panel) See the following table for more information.

Figure 60-50-3
FUNCTION /
ITEM DESCRIPTION
OPERATION

Press the top to

ADVANCED
select Hand
CONTROL SYSTEM
Controls; bottom to
(ACS) (Option)
select Foot Controls.

Press the top to

SELECTABLE
select ‘ISO’ Control
JOYSTICK
Pattern; bottom to
CONTROLS (SJC)
select ‘H’ Control
(Option)
1 Pattern.

FOUR-WAY Press the top to turn

FLASHER LIGHTS lights ON; bottom to
(Option) turn OFF.
2

P-85285F
ROTATING BEACON
(Option) Press the top to turn
This machine may be equipped with a Standard Key
OR light ON; bottom to
Panel [Figure 60-50-3].
STROBE LIGHT turn OFF.
(Option)
The Standard Key Panel has a key switch (Item 1)
[Figure 60-50-3] used to turn the loaders electrical
system on and off, and to start and stop the engine.

652 of 1052 60-50-4 T870 Service Manual

INSTRUMENT PANELS (CONT’D) The switch location (Item 5) [Figure 60-50-4] can have
different functions depending on machine configuration.
Right Panel (Keyless Start Panel) See the following table for more information.

Figure 60-50-4
FUNCTION /
ITEM DESCRIPTION
OPERATION

Press the top to

ADVANCED
1 select Hand
CONTROL SYSTEM
Controls; bottom to
(ACS) (Option)
select Foot Controls.

2 3
Press the top to
SELECTABLE
select ‘ISO’ Control
JOYSTICK
Pattern; bottom to
CONTROLS (SJC)
select ‘H’ Control
(Option)
Pattern.
4

FOUR-WAY Press the top to turn

FLASHER LIGHTS lights ON; bottom to
5 (Option) turn OFF.

P-90819M
ROTATING BEACON
(Option) Press the top to turn
This machine may be equipped with a Keyless Start
OR light ON; bottom to
Panel [Figure 60-50-4].
STROBE LIGHT turn OFF.
(Option)
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. Key Switch: Used to turn the loaders electrical

system on and off, and to start and stop the engine.

653 of 1052 60-50-5 T870 Service Manual

INSTRUMENT PANELS (CONT’D) 5. Key Switch: Used to turn the loaders electrical
system on and off, and to start and stop the engine.
Right Panel (Deluxe Instrumentation Panel)
The switch location (Item 6) [Figure 60-50-5] can have
Figure 60-50-5 different functions depending on machine configuration.
See the following table for more information.

1 FUNCTION /
ITEM DESCRIPTION
OPERATION

2
Press the top to
3 ADVANCED
select Hand
CONTROL SYSTEM
Controls; bottom to
(ACS) (Option)
select Foot Controls.

Press the top to

SELECTABLE
select ‘ISO’ Control
5 JOYSTICK
Pattern; bottom to
CONTROLS (SJC)
select ‘H’ Control
(Option)
Pattern.

6
FOUR-WAY Press the top to turn
FLASHER LIGHTS lights ON; bottom to
(Option) turn OFF.

P-90212N

This machine may be equipped with a Deluxe

Instrumentation Panel [Figure 60-50-5].
ROTATING BEACON
(Option) Press the top to turn
1. Keypad (1 through 0): The keypad has two
OR light ON; bottom to
functions:
STROBE LIGHT turn OFF.
(Option)
- 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.

654 of 1052 60-50-6 T870 Service Manual

INSTRUMENT PANELS (CONT’D) Change Language:

Right Panel (Deluxe Instrumentation Panel) (Cont’d) Press the left or right scroll button to cycle through the
languages. The language that is stopped on becomes
Figure 60-50-6 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.)

Enter The Password:

Use the numbers on the keypad to enter the password,

then press the [ENTER] button. A symbol will appear on
the display screen for each number entered. The left
scroll button can be used to backspace if an incorrect
number is entered.

If the correct password is not entered, [INVALID

NA3187 PASSWORD TRY AGAIN] will appear on the display
screen and the password will have to be reentered.
The first screen you will see on your new loader is shown See CONTROL PANEL SETUP for further description of
in [Figure 60-50-6]. screens to set up the system for your use. (See
CONTROL PANEL SETUP on Page 60-180-1.)
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 60-191-1.) Keep your
password in a safe location for future needs.

655 of 1052 60-50-7 T870 Service Manual

INSTRUMENT PANELS (CONT’D)

Left Switch Panel Right Switch Panel

Figure 60-50-7

1 1

2 2

3 3

NA3323

NOTE: Earlier models did not have switch locations

four and five on the left switch panel.
ITEM DESCRIPTION FUNCTION / OPERATION
FOUR-WAY
Press the top to turn lights
1 FLASHER
ON; bottom to turn OFF. ITEM DESCRIPTION FUNCTION / OPERATION
LIGHTS (Option)
ROTATING Press and hold the up arrow
BEACON (Option) to disengage the Bob-Tach
Press the top to turn light ON; POWER wedges. Press and hold the
2 OR
bottom to turn OFF. 1 BOB-TACH down arrow to engage the
STROBE LIGHT
(Option) (Option) Bob-Tach wedges into the
attachment mounting frame
HYDRAULIC holes.
Press the top to engage
BUCKET
3 Hydraulic Bucket Positioning; 2 NOT USED –––
POSITIONING
bottom to disengage.
(Option) Automatic Operation - middle
AUTOMATIC Press the top to engage REVERSING FAN position; Manual Operation -
3
4 RIDE CONTROL Automatic Ride Control; (Option) press top momentarily; press
(Option) bottom to disengage. bottom to disengage.

Press the top to turn lights Press the bottom to inhibit

ON; bottom to turn OFF. DeSOX. See SELECTIVE
SIDE LIGHTING DESOX INHIBIT
5 NOTE: Turn side lighting 3 CATALYTIC REDUCTION
(Option) (Option)
OFF when driving (SCR) SYSTEM
on public roads. in this manual.

656 of 1052 60-50-8 T870 Service Manual

INSTRUMENT PANELS (CONT’D) Right Side Lower Panel

Left Side Lower Panel Figure 60-50-9

Figure 60-50-8 1
2

3
1 2 4

P-85267D

P-85282

REF.
DESCRIPTION FUNCTION / OPERATION
NO.
REF.
DESCRIPTION FUNCTION / OPERATION 1 POWER PORT Provides a 12 volt
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 when started. Fan 4 SPEAKER (Option) Right speaker used with
Motor (Item 1) must be ON optional radio.
for air conditioning to
operate.
3 TEMPERATURE Turn clockwise to increase
CONTROL (Option) the temperature;
counterclockwise to
decrease.
4 SPEAKER (Option) Left speaker used with
optional radio.

657 of 1052 60-50-9 T870 Service Manual

INSTRUMENT PANELS (CONT’D)

Radio

This machine may be equipped with a radio.

Figure 60-50-10

1 2 3 4 5 6 7

9 10

11 12
8
13

14 15

17

16
NA3090

The table on the next page shows the DESCRIPTION and FUNCTION / OPERATION for each of the controls of the radio
[Figure 60-50-10].

NOTE: See DISPLAY in the table for clock setting instructions.

658 of 1052 60-50-10 T870 Service Manual

INSTRUMENT PANELS (CONT’D)

Radio (Cont’d)

ITEM DESCRIPTION FUNCTION / OPERATION

1 POWER Press to turn ON; press again to turn OFF.
Press to mute audio output; [MUTE] will appear in display screen; press again to turn
2 MUTE
OFF.
Press to toggle between function mode (showing tuner frequency, auxiliary input, weather
band information, or timer) and clock mode.
3 DISPLAY Press and hold to enter clock setting mode; use FREQUENCY DOWN (TUN -) button to
adjust hours and FREQUENCY UP (TUN +) button to adjust minutes; normal operation
will resume automatically.
4 BAND Press to select tuner mode. Press to cycle through 2 AM (MW) bands and 3 FM bands.
Press to select Auxiliary Input mode. Portable audio device (MP3 player) must be
5 AUXILIARY
attached to auxiliary input jack.
Press to select weather band; use FREQUENCY UP (TUN +) and FREQUENCY DOWN
(TUN -) buttons to adjust to the clearest station.
6 WEATHER BAND The weather alert feature, if activated, will automatically switch from the current function to
the weather band if a weather warning is received. See AUDIO / MENU ADJUSTMENT in
this table.
Press to access timer mode. Press to start the timer function; press again to stop timer;
7 TIMER
press again to resume timer or press and hold to reset timer and exit from timer mode.
8 DISPLAY SCREEN Displays the time, frequency, and activated functions.
9 VOLUME UP Adjusts volume up; current volume (0 – 40) will appear briefly in display screen.
AUDIO ADJUSTMENT: Press to cycle through bass, treble, and balance settings; use
VOLUME UP (VOL +) and VOLUME DOWN (VOL -) buttons to adjust when desired option
is displayed; normal operation will resume automatically.
MENU ADJUSTMENT: Press and hold for 3 seconds to enter menu adjustment settings;
press to cycle through the following settings; use VOLUME UP (VOL +) and VOLUME
DOWN (VOL -) buttons to adjust when desired option is displayed; normal operation will
AUDIO / MENU resume automatically.
10 • Beep Confirm (On or Off) – Determines if beep will sound with each button press.
ADJUSTMENT
• Operation Region (USA or Europe) – Selects the appropriate region.
• Clock Display (12 or 24) – Selects a 12-hour or 24-hour clock display.
• Display Brightness (Low, Medium, or High) – Determines brightness level of display
screen.
• Backlight Color (Amber or Green) – Determines backlight color of display screen.
• Power On Volume (0 – 40) – Selects default volume setting when radio is turned on.
• WB Alert (On or Off) – Determines if weather band alert feature is activated.
11 FREQUENCY DOWN Press to manually tune the radio frequency down.
12 FREQUENCY UP Press to manually tune the radio frequency up.
13 VOLUME DOWN Adjusts volume down; current volume (0 – 40) will appear briefly in display screen.
SEEK FREQUENCY
14 Press to automatically tune frequency down to next strong station.
DOWN
SEEK FREQUENCY
15 Press to automatically tune frequency up to next strong station.
UP
Used to store and recall stations for each AM and FM band. Press and hold to store
16 PRESET STATIONS
current station; press button to recall station.
AUXILIARY INPUT Connect headphone or line output of portable audio device (MP3 player) to 3,5 mm (1/8
17
JACK in) jack and press AUXILIARY button.

659 of 1052 60-50-11 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-85928A
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
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 left 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.

660 of 1052 60-50-12 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 60-50-12.)
Remove the right instrument panel. (See Left Panel
Removal And Installation on Page 60-50-12.) Figure 60-50-16

Disconnect the key switch wiring harness.

Figure 60-50-15

2
P-85947

Remove the left side instrument panel.

P-85948
Remove the retaining nut (Item 1) [Figure 60-50-16] from
the loader alarm.
Remove the key (Item 1) from the switch. Remove the
key switch retaining nut (Item 2) [Figure 60-50-15] from Remove the alarm from the loader instrument panel.
the switch.

Remove the key switch from the control panel.

661 of 1052 60-50-13 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 60-50-12.)
Remove the left panel. (See Left Panel Removal And
Installation on Page 60-50-12.) Figure 60-50-19

Figure 60-50-17

P107695
1
P-85945
Remove the fastener (Item 1) and the screw (item 2)
[Figure 60-50-19].
Remove the two fasteners (Item 1) [Figure 60-50-17].
Figure 60-50-20
Figure 60-50-18

2
2
1
P-85944A
P-85946

Remove the two screws (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].

662 of 1052 60-50-14 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

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.

663 of 1052 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

2
1
2

3
1

P-85586C

P115838
Pry the cab light (Items 1) free from the headliner (Item 2)
[Figure 60-60-7].
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 too far away from the
assembly a 1/4 turn. headliner to prevent damage to the wires.

Figure 60-60-6 Figure 60-60-8

P115839 P115307

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].

664 of 1052 60-60-2 T870 Service Manual

BOBCAT CONTOLERS (GATEWAY AND AUXILLIARY)

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 operator’s left foot.

665 of 1052 60-70-1 T870 Service Manual

BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) (CONT’D)

Connector Identification

Gateway Controller

1 1

34 26

J1A J1B

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

666 of 1052 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 BRN HYD LOCK VALVE SOLENOID GROUND
2 2990 BRN LIFT SPOOL SOLENOID GROUND
3 7050 WHT HVAC RELAY SIGNAL
4 3380 LBL SWITCHED POWER RELAY SIGNAL
5 6320 PNK MRKR LIGHT PWR RELAY SIGNAL
6 OPEN NA NA
7 8210 TAN STARTER RELAY SIGNAL
8 4110 LGN TRACTION LOCK RELAY SIGNAL
9 8100 TAN TAILGATE RELAY OUTPUT
10 2980 BRN TILT SPOOL LOCK SOLENOID GROUND
11 7021 WHT AC SIGNAL MONITOR
12 3100 LBL LEFT TAILGATE RELAY FEEDBACK
13 4150 LGN TRACTION LOCK RELAY FEEDBACK
14 OPEN NA NA
15 OPEN NA NA
16 3150 LBL AIR FILTER SENDER SIGNAL
17 6210 PNK REAR LIGHT RELAY SIGNAL
18 2910 BRN HYDRAULIC FAN GROUND
19 2380 BRN PTOL LED
20 3030 LBL PTOL SWITCH
21 3450 LBL SWITCHED POWER RELAY FEEDBACK
22 3560 LBL STARTER RELAY FEEDBACK
23 3440 LBL HYD FAN DIFF PRESS SWITCH SIGNAL
24 8130 TAN START ENGINE
25 3105 LBL RIGHT TAILGATE FAN RELAY FEEDBACK
26 2350 BRN TWO-SPEED GROUND
27 2360 BRN TWO-SPEED MAKEUP GROUND
28 3440 LBL REAR LIGHT RELAY FEEDBACK
29 OPEN NA NA
30 3050 LBL HVAC RELAY FEEDBACK
31 3460 LBL MRKR LIGHT PWR RELAY FEEDBACK
32 3220 LBL HYD TEMP SIGNAL
33 3695 LBL THROTTLE SECONDARY SIGNAL
34 3320 LBL HYD FILTER DIFF PRESS

667 of 1052 60-70-3 T870 Service Manual

BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) (CONT’D)

Connector Identification (Cont’d)

J1B

WIRE
PIN COLOR DESCRIPTION
NUMBER
1 3190 LBL HYD CHARGE PRESS SENDER SIGNAL
2 1110 RED/WHT COMPUTER FUSE POWER OUT
3 1130 RED/WHT COMPUTER FUSE POWER OUT
4 8007 TAN IGN SW ON
5 4990 LGN LIFT SPOOL LOCK SOLENOID SIGNAL
6 4200 LGN TRACTION SOLENOID OUTPUT
7 4980 LGN TILT SPOOL LOCK SOLENOID SIGNAL
8 9260 PUR CAN LO 0
9 9160 PUR/WHT CAN HI 0
10 3690 LBL TROTTLE PRIMARY SIGNAL
11 3370 LBL SEATBAR SENSOR SIGNAL
12 3180 LBL FUEL SENDER SIGNAL
13 4410 LGN HYD LOCK SOLENOID SIGNAL
14 9105 PUR/WHT CAN HIGH 1
15 2500 BLK COMPUTER GROUND
16 2510 BLK COMPUTER GROUND
17 2230 BRN SENSOR GROUND
18 3110 LBL ENGINE COOLANT SENSOR SIGNAL
19 4010 LGN HYDRAULIC FAN SIGNAL
20 9205 PUR CAN LOW 1
21 3090 LBL REMOTE RUN KEY
22 3040 LBL RUN / ENTER
23 5190 YEL HYDRAULIC CHARGE PRESSURE
24 5100 YEL +5V SUPPLY
25 4360 LGN TWO-SPEED MAKEUP
26 4350 LGN TWO-SPEED SIGNAL

668 of 1052 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

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

669 of 1052 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 BRN FRONT BASE SOLENOID GROUND
2 OPEN NA NA
3 6520 PNK LEFT BLINKER SIGNAL
4 6420 PNK RIGHT BLINKER SIGNAL
5 7200 WHT HORN SIGNAL
6 OPEN NA NA
7 3480 LBL RIDE CONTROL RELAY SIGNAL
8 OPEN NA NA
9 OPEN NA NA
10 OPEN NA NA
11 OPEN NA NA
12 OPEN NA NA
13 OPEN NA NA
14 OPEN NA NA
15 OPEN NA NA
16 3475 LBL REVERSING FAN MANUAL SIGNAL
17 OPEN NA NA
18 2330 BRN FRONT ROD SOLENOID GROUND
19 OPEN NA NA
20 OPEN NA NA
21 3415 LBL RIDE CONTROL RELAY FEEDBACK
22 OPEN NA NA
23 3410 LBL RIDE CONTROL SW AUTO
24 3095 LBL REMOTE RUN KEY
25 OPEN NA NA
26 2460 BRN HIGH FLOW SOLENOID GROUND
27 2175 BRN REVERSING FAN RETURN SIGNAL
28 OPEN NA NA
29 3470 LBL REVERSING FAN AUTO SIGNAL
30 OPEN NA NA
31 OPEN NA NA
32 OPEN NA NA
33 OPEN NA NA
34 OPEN NA NA

670 of 1052 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 1110 RED/WHT COMPUTER FUSE POWER OUT
3 1130 RED/WHT COMPUTER FUSE POWER OUT
4 OPEN NA NA
5 4440 LGN REAR BASE SIGNAL
6 OPEN NA NA
7 4430 LGN REAR ROD SIGNAL
8 9280 PUR CAN LO 0
9 9180 PUR/WHT CAN HI 0
10 3455 LBL RIDE CONTROL PRESSURE SENSOR SIGNAL
11 OPEN NA NA
12 OPEN NA NA
13 4340 LGN FRONT BASE SOLENOID SIGNAL
14 9500 PUR/WHT CAN HI 1
15 2550 BLK AUXILIARY CONTROLLER GROUND
16 2540 BLK AUXILIARY CONTROLLER GROUND
17 2185 BRN SENSOR GROUND
18 OPEN NA NA
19 4330 LGN FRONT ROD SOLENOID SIGNAL
20 9600 PUR CAN LO 1
21 OPEN NA NA
22 1560 RNG/WHT SWITCHED INPUT POWER
23 OPEN NA NA
24 5105 YEL RIDE CONTROL SENSOR +5 V PWR
25 3485 LBL REVERSING FAN SIGNAL
26 4460 LGN HIGH FLOW SOLENOID SIGNAL

671 of 1052 60-70-7 T870 Service Manual

BOBCAT CONTROLLERS (GATEWAY AND NOTE: The connectors are keyed and will only plug
AUXILIARY) (CONT’D) in one way.

Removal And Installation Figure 60-70-3

Raise the lift arms and install an approved lift arm

support device. (See Installing on Page 10-20-2.)

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

Remove the dosing control unit (DCU). (See Dosing 1

Control Unit (DCU) Removal And Installation on Page 70- 1
30-11.)

Remove the supply module. (See Supply Module 1

Removal And Installation on Page 70-30-13.) 1

Figure 60-70-1
P121180

Remove the controller mounting bolts (Item 1) [Figure

60-70-3] from the left fender.

Installation: Tighten the controller mounting bolts to 16 -

19 N•m (12 - 14 ft-lb) torque.
1
Remove the Gateway and Auxiliary controllers from the
loader.

P121182

Unplug the two harness connectors (Item 1) [Figure 60-

70-1] from the Gateway controller.

Figure 60-70-2

P121181

Unplug the two harness connectors (Item 2) [Figure 60-

70-1] from the Auxiliary controller.

672 of 1052 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 gray 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.

673 of 1052 60-71-1 T870 Service Manual

BOBCAT CONTROLLER (ACS) (CONT’D)

Connector And Wire Identification

G H
J J3A J3C
F K
E A
D B
J3C C H
G
F J
K J3B

F E
G D A
E H B
C
A J3B
B
D
J3A
C
J3C
J3A J3B

P-21843

674 of 1052 60-71-2 T870 Service Manual

BOBCAT CONTROLLER (ACS) (CONT’D)

Connector And Wire Identification (Cont’d)

J3A
WIRE
PIN COLOR DESCRIPTION
NUMBER
A 5970 YEL +5V SUPPLY POWER
B 1650 RNG/WHT SWITCHED ACS POWER
C OPEN NA NA
D 9140 PUR/WHT CAN SIGNAL HIGH ACS
E 9240 PUR CAN SIGNAL LOW ACS
F OPEN NA NA
G 2970 BRN ACTUATOR GROUND
H 2195 BLK ACS GROUND

J3B
WIRE
PIN COLOR DESCRIPTION
NUMBER
A OPEN NA NA
B OPEN NA NA
C OPEN NA NA
D OPEN NA NA
E 3990 LBL TILT ACTUATOR FEEDBACK
F OPEN NA NA
G OPEN NA NA
H 3980 LBL LIFT ACTUATOR FEEDBACK
J OPEN NA NA
K OPEN NA NA

J3C
WIRE
PIN COLOR DESCRIPTION
NUMBER
A 4640 LGN TILT ACTUATOR FORWARD
B 1090 RED/WHT UNSWITCHED ACS POWER
C 1080 RED/WHT UNSWITCHED ACS POWER
D 4610 LGN LIFT ACTUATOR MOTOR GROUND
E OPEN NA NA
F 4600 LGN LIFT ACTUATOR MOTOR POWER
G OPEN NA NA
H 2270 BLK ACS GROUND
J 2260 BLK ACS GROUND
K 4650 LGN TILT ACTUATOR REVERSE

675 of 1052 60-71-3 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 10-20-2.)
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.

NOTE: The calibration procedure must be followed

when replacing a controller. (See Lift And Tilt
Calibration (SJC) on Page 60-160-4.)
1
P100292

NOTE: Before unplugging any controller the key

switch 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.

676 of 1052 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 and the position of the ISO and drive pump is equipped with position sensors mounted to
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.

Earlier Models

RIGHT HYDRAULIC
HAND DRIVE MOTOR
PANEL CONTROL
ACS
CONTROL
LIFT / TILT
ACTUATORS
SJC
SWITCH GEAR ENGINE
INTERNAL CAN BUS

PUMP

RIGHT
JOYSTICK

FWD / REV AND

LEFT SWASH PLATE
JOYSTICK SENSORS

AUXILIARY DRIVE
CONTROL
LEFT PUMP
HAND
PANEL
HYDRAULIC
ACD
MOTOR
EXTERNAL CONTROL
GATEWAY CAN BUS
CONTROL NA5677

677 of 1052 60-72-1 T870 Service Manual

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)

Connector Identification (Earlier Models)

P-64295

678 of 1052 60-72-2 T870 Service Manual

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)

Connector Identification (Earlier Models) (Cont'd)

P100288

679 of 1052 60-72-3 T870 Service Manual

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D) Figure 60-72-3

Removal And Installation (Earlier Models)

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

Figure 60-72-1
1

P-64325

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.
P115851A
Figure 60-72-4

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!

680 of 1052 60-72-4 T870 Service Manual

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)

Later Models

SJC
SWITCH

NA13675A

681 of 1052 60-72-5 T870 Service Manual

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)

Connector Identification (Later Models)

Drive Controller

1 1

34 26

J5A J5B

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
J5A J5B P-76646
P-76645

682 of 1052 60-72-6 T870 Service Manual

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)

Connector Identification (Later Models) (Cont’d)

J5A

WIRE
PIN COLOR DESCRIPTION
NUMBER
1 OPEN NA NA
2 OPEN NA NA
3 OPEN NA NA
4 OPEN NA NA
5 OPEN NA NA
6 4275 LGN FOOT CONTROL
7 OPEN NA NA
8 4235 LGN HAND CONTROL LIGHT
9 4210 LGN BRAKE LIGHT SIGNAL
10 2670 BRN LEFT FWD GROUND
11 OPEN NA NA
12 OPEN NA NA
13 OPEN NA NA
14 OPEN NA NA
15 OPEN NA NA
16 OPEN NA NA
17 7100 WHT BACK-UP ALARM POWER
18 2680 BRN LEFT REV GROUND
19 OPEN NA NA
20 OPEN NA NA
21 4550 LGN FOOT CONTROL SIGNAL
22 OPEN NA NA
23 OPEN NA NA
24 OPEN NA NA
25 OPEN NA NA
26 2660 BRN RIGHT FWD GROUND
27 2650 BRN RIGHT REV GROUND
28 OPEN NA NA
29 OPEN NA NA
30 OPEN NA NA
31 OPEN NA NA
32 OPEN NA NA
33 OPEN NA NA
34 OPEN NA NA

683 of 1052 60-72-7 T870 Service Manual

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)

Connector Identification (Later Models) (Cont’d)

J5B

WIRE
PIN COLOR DESCRIPTION
NUMBER
1 OPEN NA NA
2 1250 RED/WHT COMPUTER FUSE POWER OUT
3 1260 RED/WHT COMPUTER FUSE POWER OUT
4 OPEN NA NA
5 OPEN NA NA
6 OPEN NA NA
7 4270 LGN LEFT FWD DRIVE
8 9290 PUR CAN LO 0
9 9190 PUR/WHT CAN HI 0
10 3810 LBL RIGHT SWASHPLATE ANGLE
11 OPEN NA NA
12 OPEN NA NA
13 OPEN NA NA
14 OPEN NA NA
15 2035 BLK CONTROLLER GROUND
16 2490 BLK CONTROLLER GROUND
17 2890 BRN SWASHPLATE SENSOR GROUND
18 3860 LBL LEFT SWASHPLATE ANGLE
19 4280 LGN LEFT REV DRIVE
20 OPEN NA NA
21 1630 RNG/WHT SWITCHED POWER RELAY SIGNAL
22 OPEN NA NA
23 5890 YEL SENSOR SUPPLY +5V POWER
24 OPEN NA NA
25 4250 LGN RIGHT REV DRIVE
26 4260 LGN RIGHT FWD DRIVE

684 of 1052 60-72-8 T870 Service Manual

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)

Removal And Installation (Later Models)

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

Figure 60-72-1

P127669

Remove the two bolts (Item 1) [Figure 60-72-1] that

secure the controller.

Remove the tie strap (Item 2) [Figure 60-72-1].

Installation: Tighten the mounting bolts to 17 - 19 N•m

(12 - 14 ft-lb) torque.

Figure 60-72-2

P127677

Unplug the two harness connectors and remove the drive

controller from the loader [Figure 60-72-2].

NOTE: The connectors are keyed and will only plug

in one way.

685 of 1052 60-72-9 T870 Service Manual

686 of 1052 60-72-10 T870 Service Manual
BOBCAT CONTROLLER (SCPA) (DRIVE) The drive controller communicates with the Gateway
controller in an SCPA system. Both of these controllers
Description are capable of software upgrades.

The drive controller is on loaders equipped with the The SCPA system uses electronic steering handles to
SCPA option. This controller processes information for control the drive functions of the loader.
the drive functions.
The hydrostatic drive pump has two electromagnetic coils
The drive controller is located underneath the operator’s on each of the two pumps to control the drive of the
cab, attached to the control panel. loader. The coils will direct the forward and reverse
outputs of the pump to the drive motors. The hydrostatic
The drive controller monitors the position of the steering drive pump is equipped with position sensors mounted to
handles and the pump swash plate angles. the bottom of the swash plates to provide feedback to the
controllers to sense uncommanded swash plate
movement.

Earlier Models

RIGHT HYDRAULIC
HAND MOTOR
PANEL DRIVE
CONTROL

GEAR ENGINE
INTERNAL CAN BUS

PUMP
RIGHT
JOYSTICK

FWD / REV AND

LEFT SWASH PLATE
JOYSTICK SENSORS

AUXILIARY
CONTROL DRIVE
PUMP
LEFT
HAND
PANEL
HYDRAULIC
ACD MOTOR
EXTERNAL CONTROL
GATEWAY CAN BUS
CONTROL
NA5679

687 of 1052 60-73-1 T870 Service Manual

BOBCAT CONTROLLER (SCPA) (DRIVE) (CONL’D)

Connector Identification (Earlier Models)

P100286

688 of 1052 60-73-2 T870 Service Manual

BOBCAT CONTROLLER (SCPA) (DRIVE) (CONT’D)

Connector Identification (Earlier Models) (Cont'd)

P1002876

689 of 1052 60-73-3 T870 Service Manual

BOBCAT CONTROLLER (SCPA) (DRIVE) (CONT’D) Figure 60-73-3

Removal And Installation (Earlier Models)

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

Figure 60-73-1
1

P-64325

Installation: Note the keyed hole in the controller socket.

(Item 1) [Figure 60-73-3]. The keyed hole matches a tab
on the connector on the wire harness.
P115851
Figure 60-73-4

Remove the three bolts (Item 1) [Figure 60-73-1] that

secure the controller.

Installation: Tighten the mounting bolts to 16 - 19 N•m

(12 - 14 ft-lb) torque.

Figure 60-73-2

J S
P-64325

Remove the drive controller [Figure 60-73-4].

1

P-64324

Remove the screw and wire harness (Item 1) [Figure 60-

73-2].

Installation: Tighten the connector screw to 3,39 - 3,96

N•m (30 - 35 in-lb) torque. DO NOT OVERTIGHTEN!

690 of 1052 60-73-4 T870 Service Manual

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)

Later Models

SJC
SWITCH

NA13675A

691 of 1052 60-73-5 T870 Service Manual

BOBCAT CONTROLLER (SCPA) (DRIVE) (CONT’D)

Connector Identification (Later Models)

Drive Controller

1 1

34 26

J5A J5B

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
J5A J5B P-76646
P-76645

692 of 1052 60-73-6 T870 Service Manual

BOBCAT CONTROLLER (SCPA) (DRIVE) (CONT’D)

Connector Identification (Later Models) (Cont’d)

J5A

WIRE
PIN COLOR DESCRIPTION
NUMBER
1 OPEN NA NA
2 OPEN NA NA
3 OPEN NA NA
4 OPEN NA NA
5 OPEN NA NA
6 4275 LGN FOOT CONTROL
7 OPEN NA NA
8 4235 LGN HAND CONTROL LIGHT
9 4210 LGN BRAKE LIGHT SIGNAL
10 2670 BRN LEFT FWD GROUND
11 OPEN NA NA
12 OPEN NA NA
13 OPEN NA NA
14 OPEN NA NA
15 OPEN NA NA
16 OPEN NA NA
17 7100 WHT BACK-UP ALARM POWER
18 2680 BRN LEFT REV GROUND
19 OPEN NA NA
20 OPEN NA NA
21 4550 LGN FOOT CONTROL SIGNAL
22 OPEN NA NA
23 OPEN NA NA
24 OPEN NA NA
25 OPEN NA NA
26 2660 BRN RIGHT FWD GROUND
27 2650 BRN RIGHT REV GROUND
28 OPEN NA NA
29 OPEN NA NA
30 OPEN NA NA
31 OPEN NA NA
32 OPEN NA NA
33 OPEN NA NA
34 OPEN NA NA

693 of 1052 60-73-7 T870 Service Manual

BOBCAT CONTROLLER (SCPA) (DRIVE) (CONT’D)

Connector Identification (Later Models) (Cont’d)

J5B

WIRE
PIN COLOR DESCRIPTION
NUMBER
1 OPEN NA NA
2 1250 RED/WHT COMPUTER FUSE POWER OUT
3 1260 RED/WHT COMPUTER FUSE POWER OUT
4 OPEN NA NA
5 OPEN NA NA
6 OPEN NA NA
7 4270 LGN LEFT FWD DRIVE
8 9290 PUR CAN LO 0
9 9190 PUR/WHT CAN HI 0
10 3810 LBL RIGHT SWASHPLATE ANGLE
11 OPEN NA NA
12 OPEN NA NA
13 OPEN NA NA
14 OPEN NA NA
15 2035 BLK CONTROLLER GROUND
16 2490 BLK CONTROLLER GROUND
17 2890 BRN SENSOR GROUND
18 3860 LBL LEFT SWASHPLATE ANGLE
19 4280 LGN LEFT REV DRIVE
20 OPEN NA NA
21 1630 RNG/WHT SWITCHED POWER RELAY SIGNAL
22 OPEN NA NA
23 5890 YEL SENSOR SUPPLY +5V POWER
24 OPEN NA NA
25 4250 LGN RIGHT REV DRIVE
26 4260 LGN RIGHT FWD DRIVE

694 of 1052 60-73-8 T870 Service Manual

BOBCAT CONTROLLER (SCPA) (DRIVE) (CONT’D)

Removal And Installation (Later Models)

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

Figure 60-73-1

P127671

Remove the two bolts (Item 1) [Figure 60-73-1] that

secure the controller.

Remove the tie strap (Item 2) [Figure 60-73-1].

Installation: Tighten the mounting bolts to 17 - 19 N•m

(12 - 14 ft-lb) torque.

Figure 60-73-2

P127677

Unplug the two harness connectors and remove the drive

controller from the loader [Figure 60-73-2].

NOTE: The connectors are keyed and will only plug

in one way.

695 of 1052 60-73-9 T870 Service Manual

696 of 1052 60-73-10 T870 Service Manual
DOSING CONTROL UNIT (DCU)

Description

The dosing control unit (DCU) is used for overall control

of the SCR system.

Removal And installation

DCU removal and installation. (See Dosing Control Unit

(DCU) Removal And Installation on Page 70-30-11.)

697 of 1052 60-80-1 T870 Service Manual

698 of 1052 60-80-2 T870 Service Manual
ENGINE CONTROL UNIT (ECU) Figure 60-90-1

Description

The engine ECU controls the amount, timing, mixture

and pressure of fuel that is injected. The engine ECU
operates each kind of control based on the signals from
each type of sensor.

The actuator for controlling the amount, timing and

mixture of fuel injection is the injector, while the actuator
for controlling fuel pressure is the high pressure pump.

The amount of fuel to be injected is determined using a

basic injection amount, which is calculated based on the
state of the engine and driving conditions, with P115852
corrections added for parameters such as water
temperature, fuel temperature, intake pressure, etc.
The ECU is located in the engine compartment on the
The ECU controls the timing for starting to energize the right hand upright [Figure 60-90-1].
injectors, first determining the timing for the main
injection and then the other injections, such as pilot
injections.

By conducting a pilot injection, the initial fuel mixture is IMPORTANT

kept to a minimum, mitigating the explosive initial
combustion and reducing NOx and noise. Avoid damage to the Engine Control Unit (ECU).
Water entering ECU atmospheric pressure sensor
The ECU calculates the set fuel injection pressure based will damage the ECU. Do not use high water pressure
on the engine load (last injection amount and engine around the ECU when cleaning the engine
RPM) and controls the amount the high pressure pump compartment.
supplies and the fuel pressure inside the rail. I-2357-0512

699 of 1052 60-90-1 T870 Service Manual

ENGINE CONTROL UNIT (ECU) (CONT’D) Figure 60-90-4

Cleaning

NOTE: The ECU connectors must to be free of all dirt

and debris before removing connectors.

NOTE: ECU removed for photo quality. 1

Figure 60-90-2

P114460

Remove any residual dirt and debris from the connector

and slide area with a small brush (Item 1) [Figure 60-90-
4].

2 Repeat all steps until there is no visible evidence of dirt,

grit or other debris.
P114458
NOTE: Inspect the connector and repeat cleaning
Use a spray bottle (Item 1) to apply water around the process if debris remains on the connector
connector (Item 2) [Figure 60-90-2] to remove dirt and and ECU.
debris.
Figure 60-90-5
NOTE: Do not apply water when any connector is
removed.

Figure 60-90-3 2 3

1
1

P114461

Inspect the connector (Item 1) [Figure 60-90-5] for

2 damage and debris.
P114459
NOTE: To avoid getting debris in the terminal
openings, clean the connector facing the
Use air pressure to remove loose particles from the ECU ground.
head (Item 1) and the connector (Item 2) [Figure 60-90-
3]. Using a clean damp cloth or paper towel, not dripping
wet, brush off the heavy deposits on the housing (Item 2)
The connectors should be dry before disconnecting. but do not wipe on the terminal openings (Item 3) [Figure
60-90-5].

700 of 1052 60-90-2 T870 Service Manual

ENGINE CONTROL UNIT (ECU) (CONT’D) Figure 60-90-8

Removal And Installation

1
IMPORTANT 2

Avoid damaging the Engine Control Unit (ECU) and

electrical connectors. Use care when removing or
installing the ECU connectors.
I-2356-0512

Clean the connectors before removal. (See Cleaning on

Page 60-90-2.) P114357

NOTE: SCR removed for photo quality.

Figure 60-90-9
Figure 60-90-6

1
1

P114465
P115872

Lift the lever (Item 1) and push fully forward to remove

Remove the connectors (Item 1) from the ECU (Item 2) connector (Item 2) [Figure 60-90-8]. Pull connector
[Figure 60-90-6]. straight out to avoid damage [Figure 60-90-9].

Figure 60-90-7 NOTE: Removing or installing the connector at an

extreme angle will result in seal “scooping”,
creating an environment for fluid ingress.
Damage to the header or connector may
result if undue force is used.

NOTE: If resistance is encountered when opening the

1 lever, lock connector and repeat the cleaning
process.

Repeat the above procedure on the remaining connector.

P114356

Push the lock tab (Item 1) [Figure 60-90-7] in to release

the lock lever.

701 of 1052 60-90-3 T870 Service Manual

ENGINE CONTROL UNIT (ECU) (CONT’D) Figure 60-90-12

Removal And Installation (Cont’d)

Figure 60-90-10 3

1
1 1
2
P114402

Remove the nuts (Item 1) and the ECU (Item 2) from the
bracket (Item3) [Figure 60-90-12].
P115873

Remove the mounting bolts (Item 1) [Figure 60-90-11].

Figure 60-90-11

P115874

Remove the nut and the ground wire (Item 1) [Figure 60-
90-11] from the ECU.

702 of 1052 60-90-4 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 60-100-1 using the Deluxe Instrumentation Panel.

1
Press a scroll button (Item
1) repeatedly until the
Active Warnings screen
icon (Inset) is highlighted.
1 1

2 The ACTIVE WARNINGS

screen displays active
NA3272 service codes. Press [9] to
view the next service code
Press the Information button (Item 2) to cycle the data if more than one is
display (Item 1) [Figure 60-100-1] until the service code present. Press [4] to
screen is displayed. If more than one service code is display a history of service
present, the codes will scroll on the data display. codes.
The WARNINGS
When no service code is present, [NONE] is displayed HISTORY screen will list
[Figure 60-100-1]. the Service Code Number
(CODE), Hourmeter
NOTE: Corroded or loose grounds can cause reading when the error
multiple service codes and / or abnormal occurred (HOUR), and the
symptoms. All instrument panel lights User (USER) who was
flashing, alarm sounding, headlights and logged in to operate the
taillights flashing, can indicate a bad ground. machine when the error
The same symptoms can apply if the voltage occurred.
is low, such as loose or corroded battery Press [9] to view the next eight service codes.
cables. If you observe these symptoms, check
grounds and positive leads first. A total of 40 codes can be stored. When more than 40
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 the left scroll button

to back up one screen.

703 of 1052 60-100-1 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D) The following letter codes may be displayed:

Service Codes List

CODE DESCRIPTION
Figure 60-100-2 The controller is asking for a password.
CODE (Keyless Start and Deluxe Instrumentation
Panels only.)
1 2
The engine controller has determined the
COLD
engine must warm up.
The engine is performing a DeSOX process.
Operate the machine under load. (See
DESOX
SELECTIVE CATALYTIC REDUCTION (SCR)
SYSTEM on Page 70-30-1.)
Operator cab door is open. (Lift and Tilt
DOOR
functions will not operate.)
The wrong password was entered. (Keyless
ERROR
Start and Deluxe Instrumentation Panels only.)
NA3077 One or both instrument panel(s) not
NA3084 REPLY
NA3272 communicating with the controller.
Reversing fan is disabled. (See Hydraulic
RFOFF
Service codes can be either letters (Item 1) or numbers Reversing Fan Description on Page 70-60-4.)
(Item 2) [Figure 60-100-2]. SHTDN A shutdown condition exists.

CODE DESCRIPTION CODE DESCRIPTION

A0618 Wheel speed out of range A8205 ACD output ‘C’ short to battery
A3623 ACD not programmed A8206 ACD output ‘C’ short to ground
A4621 5 volt sensor supply out of range high A8207 ACD output ‘C’ open circuit
A4622 5 volt sensor supply out of range low A8232 ACD output ‘C’ overcurrent
A4721 8 volt sensor supply out of range high A8302 ACD output ‘D’ error ON
A4722 8 volt sensor supply out of range low A8303 ACD output ‘D’ error OFF
A7701 Machine key active A8305 ACD output ‘D’ short to battery
A7901 E-Stop active A8306 ACD output ‘D’ short to ground
A8002 ACD output ‘A’ error ON A8307 ACD output ‘D’ open circuit
A8003 ACD output ‘A’ error OFF A8332 ACD output ‘D’ overcurrent
A8005 ACD output ‘A’ short to battery A8402 ACD output ‘E’ error ON
A8006 ACD output ‘A’ short to ground A8403 ACD output ‘E’ error OFF
A8007 ACD output ‘A’ open circuit A8405 ACD output ‘E’ short to battery
A8032 ACD output ‘A’ overcurrent A8406 ACD output ‘E’ short to ground
A8102 ACD output ‘B’ error ON A8407 ACD output ‘E’ open circuit
A8103 ACD output ‘B’ error OFF A8432 ACD output ‘E’ overcurrent
A8105 ACD output ‘B’ short to battery A8502 ACD output ‘F’ error ON
A8106 ACD output ‘B’ short to ground A8503 ACD output ‘F’ error OFF
A8107 ACD output ‘B’ open circuit A8505 ACD output ‘F’ short to battery
A8132 ACD output ‘B’ overcurrent A8506 ACD output ‘F’ short to ground
A8202 ACD output ‘C’ error ON A8507 ACD output ‘F’ open circuit
A8203 ACD output ‘C’ error OFF A8532 ACD output ‘F’ overcurrent

704 of 1052 60-100-2 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

Drive right rear wheel angle sensor out of range
A8602 ACD output ‘G’ error ON D7525
high
Drive left rear wheel angle sensor out of range
A8603 ACD output ‘G’ error OFF D7526
high
A8605 ACD output ‘G’ short to battery D7527 Drive left swash plate out of position
A8606 ACD output ‘G’ short to ground D7528 Drive right swash plate out of position
A8607 ACD output ‘G’ open circuit D7529 Drive left joystick X-axis out of range low
A8702 ACD output ‘H’ error ON D7531 Drive left joystick Y-axis out of range low
A8703 ACD output ‘H’ error OFF D7532 Drive right joystick Y-axis out of range low
Drive right front wheel angle sensor out of range
A8705 ACD output ‘H’ short to battery D7533
low
Drive left front wheel angle sensor out of range
A8706 ACD output ‘H’ short to ground D7534
low
Drive right rear wheel angle sensor out of range
A8707 ACD output ‘H’ open circuit D7535
low
Drive left rear wheel angle sensor out of range
A8802 Reversing solenoid error ON D7536
low
A8803 Reversing solenoid error OFF D7537 Drive 5 volt sensor supply 1 out of range low
D7538 Drive 5 volt sensor supply 2 out of range low
D3905 Left joystick X-axis not in NEUTRAL D7539 Drive left swash plate sensor out of range high
D3907 Left joystick Y-axis not in NEUTRAL D7540 Drive left swash plate sensor out of range low
D4007 Right joystick Y-axis not in NEUTRAL D7541 Drive right swash plate sensor out of range high
D7501 Drive CAN joystick information error D7542 Drive right swash plate sensor out of range low
D7504 Drive no communication from drive controller D7543 Drive left forward drive solenoid error ON
D7505 Drive left joystick X-axis not in NEUTRAL D7544 Drive left reverse drive solenoid error ON
D7507 Drive left joystick Y-axis not in NEUTRAL D7545 Drive right forward drive solenoid error ON
D7508 Drive right joystick Y-axis not in NEUTRAL D7546 Drive right reverse drive solenoid error ON
Drive operating mode switch short to ground or
D7509 D7547 Drive right front steer extend short to battery
battery
D7510 Drive improper joysticks installed D7548 Drive left front steer extend short to battery
D7511 Drive left speed sensor not connected D7549 Drive right rear steer extend short to battery
D7512 Drive right speed sensor not connected D7550 Drive left rear steer extend short to battery
D7513 Drive right front wheel angle sensor stuck D7551 Drive steer pressure short to battery
D7514 Drive left front wheel angle sensor stuck D7552 Drive back-up alarm error ON
D7515 Drive right rear wheel angle sensor stuck D7553 Drive left forward drive solenoid error OFF
D7516 Drive left rear wheel angle sensor stuck D7554 Drive left reverse drive solenoid error OFF
D7517 Drive left swash plate not in NEUTRAL D7555 Drive right forward drive solenoid error OFF
D7518 Drive right swash plate not in NEUTRAL D7556 Drive right reverse drive solenoid error OFF
D7519 Drive left joystick X-axis out of range high D7557 Drive right front steer extend short to ground
D7521 Drive left joystick Y-axis out of range high D7558 Drive right front steer retract short to ground
D7522 Drive right joystick Y-axis out of range high D7559 Drive left front steer extend short to ground
Drive right front wheel angle sensor out of range
D7523 D7560 Drive left front steer retract short to ground
high
Drive left front wheel angle sensor out of range
D7524 D7561 Drive right rear steer extend short to ground
high

705 of 1052 60-100-3 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

D7562 Drive right rear steer retract short to ground E00002704 EGR actuator position fault
D7563 Drive left rear steer extend short to ground E00002709 EGR actuator position fault
D7564 Drive left rear steer retract short to ground E00002710 EGR actuator position fault
D7565 Drive steer pressure short to ground E00002720 EGR position learning fault
D7566 Drive back-up alarm error OFF E00002730 EGR position learning fault
D7567 Drive no communication from Bobcat controller E00002903 Throttle position sensor fault
D7568 Drive angle sensors not calibrated E00002904 Throttle position sensor fault
D7569 Drive battery voltage out of range high E00008100 SCR fault
Drive interrupted power (also occurs after
D7570 E00008107 SCR fault
software updates)
D7571 Drive battery voltage out of range low E00008111 SCR fault
D7572 Drive pump not calibrated E00009102 Throttle position sensor fault
Drive operating mode switch flipped while
D7573 E00009103 Throttle position sensor fault
operating
D7574 Drive right wheel speed uncommanded motion E00009104 Throttle position sensor fault
D7575 Drive left wheel speed uncommanded motion E00009119 Throttle position sensor fault
D7576 Drive no communication from ACS controller E00009411 Rail pressure control fault
D7577 Drive left speed sensor out of range high E00009416 Rail pressure control fault
D7578 Drive right speed sensor out of range high E00009418 Rail pressure control fault
D7579 Drive left speed sensor out of range low E00009703 Water in fuel sensor fault
D7580 Drive right speed sensor out of range low E00009704 Water in fuel sensor fault
D7581 Drive right front steer retract short to battery E00009709 Water in fuel sensor fault
D7582 Drive left front steer retract short to battery E00009731 Water in fuel detected
D7583 Drive right rear steer retract short to battery E00010001 Engine oil pressure too low
D7584 Drive left rear steer retract short to battery E00010003 Engine oil pressure fault
D7585 Drive 5 volt sensor supply 1 out of range high E00010004 Engine oil pressure fault
D7586 Drive 5 volt sensor supply 2 out of range high E00010203 Intake air pressure sensor fault
D7587 Drive software update required E00010204 Intake air pressure sensor fault
D7588 Drive switched power stuck ON E00010502 Intake manifold temperature fault
D7589 Drive switched power error OFF E00010503 Intake manifold temperature sensor fault
D7590 Drive calibration performed E00010504 Intake manifold temperature sensor fault
D7591 Drive left swash plate sensor reversed E00010509 Intake manifold temperature sensor fault
D7592 Drive right swash plate sensor reversed E00010510 Intake manifold temperature sensor fault
D7593 Drive unresponsive right speed sensor E00010603 Manifold pressure sensor fault
D7594 Drive unresponsive left speed sensor E00010604 Manifold pressure sensor fault
D7595 Drive left speed sensor reverse direction E00010609 Manifold pressure sensor fault
D7596 Drive right speed sensor reverse direction E00010803 Barometric pressure fault
D7597 Drive controller programmed E00010804 Barometric pressure fault
D7598 Drive controller in calibration mode E00010809 Barometric pressure fault
Drive AWS controller in wheel position
D7599 E00011000 Engine temperature extremely high
calibration mode
E00011002 Engine coolant temperature fault
E00002700 EGR control fault E00011003 Water temperature sensor fault
E00002701 EGR control fault E00011004 Water temperature sensor fault
E00002703 EGR actuator position fault E00011031 Engine coolant temperature sensor fault

706 of 1052 60-100-4 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

E00013200 Intake air volume fault E00063602 Crank position sensor fault
E00013201 Intake air volume fault E00063607 Cam or crank sensor fault
E00013203 MAF sensor fault E00063608 Crank position sensor fault
E00013204 MAF sensor fault E00063611 Crank position sensor fault
E00013209 MAF sensor fault E00063702 Cam signal fault
E00013215 Boost pressure fault E00063708 Cam signal fault
E00013231 MAF sensor fault E00063720 Cam signal fault
E00015700 Rail pressure fault E00063730 Cam signal fault
E00015702 Rail pressure sensor fault E00063919 ECU communication error
E00015703 Rail pressure sensor fault E00064103 Boost control fault
E00015704 Rail pressure sensor fault E00064104 Boost control fault
E00015710 Rail pressure fault E00065103 Injector #1 fault
E00015711 Rail pressure fault E00065105 Injector #1 fault
E00015721 Rail pressure control fault E00065106 Injector #1 fault
E00015722 Rail pressure control fault E00065120 Injector #1 fault
E00016803 System voltage too high E00065121 Injector #1 fault
E00016804 System voltage too low E00065131 Injector #1 fault
E00017103 MAF sensor fault E00065203 Injector #2 fault
E00017104 MAF sensor fault E00065205 Injector #2 fault
E00017200 Intake air temperature too high E00065206 Injector #2 fault
E00017202 Intake air temperature sensor fault E00065220 Injector #2 fault
E00017203 Intake air temperature sensor fault E00065221 Injector #2 fault
E00017204 Intake air temperature sensor fault E00065231 Injector #2 fault
E00017209 Intake air temperature sensor fault E00065303 Injector #3 fault
E00017300 Exhaust over temperature fault E00065305 Injector #3 fault
E00017301 DOC exothermal efficiency fault E00065306 Injector #3 fault
E00017302 SCR inlet temperature sensor fault E00065320 Injector #3 fault
E00017400 Fuel temperature too high E00065321 Injector #3 fault
E00017402 Fuel temperature fault E00065331 Injector #3 fault
E00017403 Fuel temperature sensor fault E00065403 Injector #4 fault
E00017404 Fuel temperature sensor fault E00065405 Injector #4 fault
E00017409 Fuel temperature sensor fault E00065406 Injector #4 fault
E00017502 Engine oil temperature fault E00065420 Injector #4 fault
E00017531 Engine oil temperature sensor fault E00065421 Injector #4 fault
E00019000 Engine speed extremely high E00065431 Injector #4 fault
E00062802 ECU fault E00067603 Glow plug relay fault
E00062912 ECU fault E00067604 Glow plug relay fault
E00063011 Injector data fault E00067605 Glow plug relay fault
E00063023 ECU fault E00072302 Camshaft position sensor fault
E00063024 ECU fault E00072308 Camshaft position sensor fault
E00063025 ECU fault E00073120 Accelerometer fault
E00063031 ECU fault E00073121 Accelerometer fault
E00063307 Rail pressure fault E00107600 Rail pressure control fault
E00063600 Crank position sensor fault E00107601 Rail pressure control fault
E00063601 Crank position sensor fault E00107603 Rail pressure control fault

707 of 1052 60-100-5 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

E00107604 Rail pressure control fault E00122130 ECU fault
E00107609 Rail pressure control fault E00122131 ECU safety monitoring fault
E00107615 Rail pressure control fault E00122132 ECU fault
E00107616 Rail pressure control fault E00122133 ECU fault
E00107617 Rail pressure control fault E00122134 ECU fault
E00107618 Rail pressure control fault E00122135 ECU fault
E00107620 Rail pressure control fault E00122136 ECU fault
E00107631 Rail pressure control fault E00122137 ECU fault
E00107702 ECU fault E00122138 ECU fault
E00118002 Turbo temperature fault E00122139 ECU fault
E00118003 Turbo temperature sensor fault E00122140 ECU fault
E00118004 Turbo temperature sensor fault E00122141 ECU fault
E00118009 Turbo temperature sensor fault E00122142 ECU fault
E00118010 Turbo temperature sensor fault E00122143 ECU fault
E00118031 Turbo temperature sensor fault E00122144 ECU fault
E00122100 ECU fault E00122145 ECU fault
E00122101 ECU fault E00122146 ECU fault
E00122102 ECU fault E00122147 ECU fault
E00122103 ECU safety monitoring fault E00122148 ECU fault
E00122104 ECU safety monitoring fault E00122149 ECU fault
E00122105 ECU fault E00122150 ECU fault
E00122106 ECU fault E00122151 ECU fault
E00122107 ECU fault E00122152 ECU fault
E00122108 ECU fault E00122153 ECU fault
E00122109 ECU fault E00122154 ECU fault
E00122110 ECU fault E00122155 ECU fault
E00122111 ECU safety monitoring fault E00122156 ECU fault
E00122112 ECU fault E00122157 ECU fault
E00122113 ECU fault E00122158 ECU fault
E00122114 ECU fault E00122159 ECU fault
E00122115 ECU fault E00122160 ECU fault
E00122116 ECU fault E00122161 ECU fault
E00122117 ECU fault E00122162 ECU fault
E00122118 ECU fault E00122163 ECU fault
E00122119 ECU safety monitoring fault E00122164 ECU fault
E00122120 ECU fault E00122165 ECU fault
E00122121 ECU fault E00122166 ECU fault
E00122122 ECU fault E00122167 ECU fault
E00122123 ECU fault E00122168 ECU fault
E00122124 ECU fault E00122169 ECU fault
E00122125 ECU fault E00122170 ECU fault
E00122126 ECU safety monitoring fault E00122171 ECU fault
E00122127 ECU safety monitoring fault E00122172 ECU fault
E00122128 ECU safety monitoring fault E00122173 ECU fault
E00122129 ECU safety monitoring fault E00122174 ECU fault

708 of 1052 60-100-6 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

E00122175 ECU fault E00324204 Exhaust gas temperature sensor fault
E00122176 ECU fault E00324216 Exhaust gas temperature sensor fault
E00122177 ECU fault E00324600 Exhaust temperature extremely high
E00122178 ECU fault E00324603 EGR temperature sensor fault
E00122179 ECU fault E00324604 EGR temperature sensor fault
E00122180 ECU fault E00324616 Exhaust gas temperature sensor fault
E00122181 ECU fault E00325100 Differential pressure sensor fault
E00122182 ECU fault E00325101 Differential pressure sensor fault
E00122183 ECU fault E00325103 EGR temperature sensor fault
E00122184 ECU fault E00325104 EGR temperature sensor fault
E00122185 ECU fault E00325200 Exhaust temperature too high
E00122186 ECU fault E00350903 Sensor supply voltage fault
E00122187 ECU fault E00350904 Sensor supply voltage fault
E00122188 ECU fault E00350911 5 volt sensor supply #1 fault
E00122189 ECU fault E00351003 Sensor supply voltage fault
E00122190 ECU fault E00351004 Sensor supply voltage fault
E00122191 ECU fault E00351011 5 volt sensor supply #2 fault
E00122192 ECU fault E00351111 5 volt aux sensor supply #2 fault
E00122193 ECU fault E00370100 Particulate matter extremely high
E00122194 ECU fault E00370115 Particulate matter warning
E00122195 ECU fault E00370116 Particulate matter too high
E00122196 ECU fault E00408203 Inlet metering valve fault
E00122197 ECU fault E00408204 Inlet metering valve fault
E00122198 ECU fault E00408205 Inlet metering valve fault
E00122199 ECU fault E00408206 Inlet metering valve fault
E00123901 High pressure fuel leak E00425600 Unknown SCR fault
E00134703 High pressure pump fault E00476500 Exhaust temperature extremely high
E00134704 High pressure pump fault E00476503 Exhaust gas temperature sensor fault
E00134707 High pressure pump fault E00476504 Exhaust gas temperature sensor fault
E00148502 ECU main relay fault E00476518 Exhaust gas temperature sensor fault
E00148507 ECU main relay fault E00524600 DEF level empty
E00148511 ECU main relay fault E00524615 DEF level too low
E00161203 Injector #1 and #4 fault E00524616 DEF level extremely low
E00161204 Injector #1 and #4 fault E00524617 DEF level too low
E00161211 Injector #1 and #4 fault E00524619 DCU CAN communication fault
E00161303 Injector #2 and #3 fault E00524621 Blocked EGR fault
E00161304 Injector #2 and #3 fault E00524622 Dosing interrupted fault
E00161311 Injector #2 and #3 fault E00524623 DEF consumption fault
E00279103 EGR motor fault E00524624 DEF quality fault
E00279104 EGR motor fault E00524625 Tampering fault
E00279105 EGR motor fault E00524626 DEF consumption fault
E00279107 EGR blocked fault E00532403 Glow plug signal fault
E00279108 EGR position fault E00532404 Glow plug signal fault
E00324200 Exhaust temperature extremely high E52352302 Injector #1 and #4 fault
E00324203 Exhaust gas temperature sensor fault E52352303 Injector #1 and #4 fault

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DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

E52352304 Injector #1 and #4 fault E52360402 ECU communication fault
E52352402 Injector #2 and #3 fault E52370013 ECU fault
E52352403 Injector #2 and #3 fault
E52352404 Injector #2 and #3 fault H0921 Boost sensor out of range high
E52352501 Injector fault H0922 Boost sensor out of range low
E52352702 ECU fault H1221 Right thumb switch out of range high
E52353500 Injector fault H1222 Right thumb switch out of range low
E52353602 EGR fault H1224 Right thumb switch not in NEUTRAL
E52353702 EGR fault H1321 Left thumb switch out of range high
E52353802 ECU fault H1322 Left thumb switch out of range low
E52353807 ECU fault H1324 Left thumb switch not in NEUTRAL
E52353902 Fuel pump fault H1421 Lift base pressure out of range high
E52354002 Fuel pump fault H1422 Lift base pressure out of range low
E52354103 EGR fault H1502 Ride control output error ON
E52354104 EGR fault H1503 Ride control output error OFF
E52354302 Throttle position sensor fault H1507 Ride control output open circuit
E52354403 Intake heater fault H1528 Ride control output failure
E52354404 Intake heater fault H1602 Ride control relay error ON
E52354702 ECU communication error H1603 Ride control relay error OFF
E52354802 ECU communication error H2105 Reverse fan solenoid short to battery
E52357204 EGR position sensor fault H2106 Reverse fan solenoid short to ground
E52357403 EGR actuator fault H2107 Reverse fan solenoid open circuit
E52357404 EGR actuator fault H2132 Reverse fan solenoid overcurrent
E52357507 EGR actuator fault H2305 Rear base output short to battery
E52357602 EGR motor fault H2306 Rear base output short to ground
E52357702 EGR temperature sensor fault H2307 Rear base output open circuit
E52357802 EGR fault H2332 Rear base output overcurrent
E52358002 Intake throttle fault H2405 Rear rod output short to battery
E52358203 Intake throttle lift sensor fault H2406 Rear rod output short to ground
E52358204 Intake throttle lift sensor fault H2407 Rear rod output open circuit
E52358917 Low water temperature in parked regeneration H2432 Rear rod output overcurrent
E52359016 Parked regeneration time out H2502 Diverter #2 short to battery
E52359102 ECU communication fault H2503 Diverter #2 short to ground
E52359202 ECU communication fault H2505 Diverter #2 short to battery
E52359302 ECU communication fault H2506 Diverter #2 short to ground
E52359402 ECU communication fault H2507 Diverter #2 open circuit
E52359502 ECU communication fault H2605 Front base output short to battery
E52359602 ECU communication fault H2606 Front base output short to ground
E52359800 DOC failure H2607 Front base output open circuit
E52359802 ECU communication fault H2632 Front base output overcurrent
E52359900 Exhaust temperature sensor fault H2705 Front rod output short to battery
E52360000 Pump calibration error H2706 Front rod output short to ground
E52360100 Exhaust gas temperature sensor fault H2707 Front rod output open circuit
E52360200 DPF fault H2732 Front rod output overcurrent
E52360315 Water temperature sensor fault H2805 Diverter short to battery

710 of 1052 60-100-8 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

H2806 Diverter short to ground M0311 System voltage extremely high
H2807 Diverter open circuit M0314 System voltage extremely low
H2905 High-flow short to battery M0322 System voltage out of range low
H2906 High-flow short to ground M0409 Engine oil pressure too low
H2907 High-flow open circuit M0414 Engine oil pressure extremely low
H2932 High-flow overcurrent M0415 Engine oil pressure in shutdown
H3128 Interrupted power failure M0421 Engine oil pressure out of range high
H3648 Multiple ACD conflict error M0422 Engine oil pressure out of range low
H3904 Left joystick in error M0509 Hydraulic charge pressure too low
H3912 Left joystick thumb switch not in NEUTRAL M0510 Hydraulic charge pressure too high
H3913 Left joystick grip no communication M0511 Hydraulic charge pressure extremely high
H3916 Left joystick no communication M0514 Hydraulic charge pressure extremely low
H3928 Left joystick internal failure M0515 Hydraulic charge pressure in shutdown
H3948 Left joystick multiple M0521 Hydraulic charge pressure out of range high
H4004 Right joystick in error M0522 Hydraulic charge pressure out of range low
H4012 Right joystick thumb switch not in NEUTRAL M0610 Engine speed too high
H4013 Right joystick grip no communication M0611 Engine speed extremely high
H4016 Right joystick no communication M0613 Engine speed no signal
H4028 Right joystick internal failure M0615 Engine speed in shutdown
H4048 Right joystick multiple M0618 Engine speed out of range
H4302 Horn error ON M0634 Engine speed invalid information from ECU
H4303 Horn error OFF M0710 Hydraulic fluid temperature too high
H4423 Auxiliary not programmed M0711 Hydraulic fluid temperature extremely high
H4497 Auxiliary controller programmed M0715 Hydraulic fluid temperature in shutdown
H4502 Right blinker error ON M0721 Hydraulic fluid temperature out of range high
H4503 Right blinker error OFF M0722 Hydraulic fluid temperature out of range low
H4602 Left blinker error ON M0810 Engine coolant temperature too high
H4603 Left blinker error OFF M0811 Engine coolant temperature extremely high
H4721 8 volt sensor supply out of range high M0815 Engine coolant temperature in shutdown
H4722 8 volt sensor supply out of range low M0821 Engine coolant temperature out of range high
H7404 Main controller no communication M0822 Engine coolant temperature out of range low
M0826 Engine coolant temperature pre-shutdown
L0102 Lights button error ON M0909 Fuel level too low
L0202 High-flow enable button error ON M0921 Fuel level out of range high
L0302 Auxiliary enable button error ON M0922 Fuel level out of range low
L0402 Information button error ON M1016 Hydraulic charge filter not connected
L7404 Main controller no communication M1017 Hydraulic charge filter plugged
L7672 Left display panel needs programming M1121 Seat bar sensor out of range high
M1122 Seat bar sensor out of range low
M0116 Air filter not connected M1128 Seat bar sensor
M0117 Air filter plugged M1210 Intake air temperature too high
M0216 Hydraulic / Hydrostatic filter not connected M1211 Intake air temperature extremely high
M0217 Hydraulic / Hydrostatic filter plugged M1305 Fuel hold solenoid short to battery
M0309 System voltage too low M1306 Fuel hold solenoid short to ground
M0310 System voltage too high M1307 Fuel hold solenoid open circuit

711 of 1052 60-100-9 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

M1402 Fuel pull solenoid error ON M2722 Throttle primary sensor out of range low
M1403 Fuel pull solenoid error OFF M2821 Throttle secondary sensor out of range high
M1407 Fuel pull solenoid open circuit M2822 Throttle secondary sensor out of range low
M1428 Fuel pull solenoid failure M2899 Throttle secondary sensor not calibrated
M1502 Traction lock pull output error ON M2910 Exhaust gas temperature too high
M1503 Traction lock pull output error OFF M3028 Controller memory failure
M1507 Traction lock pull output open circuit M3128 Interrupted power failure
ACS (AHC) no communication to Bobcat
M1528 Traction lock pull output failure M3204
controller
M1605 Traction lock hold solenoid short to battery M3304 Deluxe panel no communication
M1606 Traction lock hold solenoid short to ground M3404 Deluxe panel in error
M1607 Traction lock hold solenoid open circuit M3505 Hydraulic fan short to battery
M1705 Hydraulic lock valve short to battery M3506 Hydraulic fan short to ground
M1706 Hydraulic lock valve short to ground M3507 Hydraulic fan open circuit
M1707 Hydraulic lock valve open circuit M3532 Hydraulic fan overcurrent
M1732 Hydraulic lock valve overcurrent M3705 Two-speed second output short to battery
M1805 Lift spool lock output short to battery M3706 Two-speed second output short to ground
M1806 Lift spool lock output short to ground M3707 Two-speed second output open circuit
M1807 Lift spool lock output open circuit M3732 Two-speed second output overcurrent
M1832 Lift spool lock output overcurrent M3805 Auxiliary hydraulic lock short to battery
M1910 Engine compartment temperature too high M3806 Auxiliary hydraulic lock short to ground
Engine compartment temperature extremely
M1911 M3807 Auxiliary hydraulic lock open circuit
high
Engine compartment temperature out of range
M1921 M3832 Auxiliary hydraulic lock overcurrent
high
Engine compartment temperature out of range
M1922 M4028 Wrong ECU detected
low
M2005 Two-speed primary solenoid short to battery M4109 Alternator voltage too low
M2006 Two-speed primary solenoid short to ground M4110 Alternator voltage high
M2007 Two-speed primary solenoid open circuit M4111 Alternator voltage extremely high
M2032 Two-speed primary solenoid overcurrent M4228 Wrong DCU detected
M2102 Glow plug output error ON M4304 Keyless panel no communication
M2103 Glow plug output error OFF M4404 Auxiliary no communication
M2107 Glow plug output open circuit M4510 Water in fuel sensor too high
M2128 Glow plug output failure M4511 Water in fuel sensor extremely high
M2202 Starter output error ON M4521 Water in fuel sensor out of range high
M2203 Starter output error OFF M4522 Water in fuel sensor out of range low
M2207 Starter output open circuit M4530 Water in fuel sensor fault
M2228 Starter output failure M4621 5 volt sensor supply out of range high
M2302 Starter relay error ON M4622 5 volt sensor supply out of range low
M2303 Starter relay error OFF M4721 8 volt sensor supply out of range high
M2402 Fuel pull relay error ON M4722 8 volt sensor supply out of range low
M2403 Fuel pull relay error OFF M4802 Front light relay error ON
M2502 Traction pull relay error ON M4803 Front light relay error OFF
M2503 Traction pull relay error OFF M4902 Rear light relay error ON
M2602 Glow plug relay error ON M4903 Rear light relay error OFF
M2603 Glow plug relay error OFF M5002 Front light output error ON
M2721 Throttle primary sensor out of range high M5003 Front light output error OFF

712 of 1052 60-100-10 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

M5007 Front light output open circuit M7007 Switched power output open circuit
M5028 Front light output failure M7028 Switched power output failure
M5102 Rear light output error ON M7102 Electric fan output error ON
M5103 Rear light output error OFF M7103 Electric fan output error OFF
M5107 Rear light output open circuit M7107 Electric fan output open circuit
M5128 Rear light output failure M7202 Electric fan relay error ON
M5202 Press to operate button error ON M7203 Electric fan relay error OFF
M5221 Press to operate button out of range high M7304 Remote control no communication
M5222 Press to operate button out of range low M7316 Remote control no communication to transmitter
M5305 Press to operate light short to battery M7423 Main controller not programmed
M5306 Press to operate light short to ground M7472 Main controller needs programming
M5405 Tilt spool lock short to battery M7497 Main controller programmed
M5406 Tilt spool lock short to ground M7504 Drive no communication
M5407 Tilt spool lock open circuit M7604 Left display panel no communication
M5432 Tilt spool lock overcurrent M7748 Key switch multiple
M5810 Fuel temperature too high M7839 Hourmeter changed
M5811 Fuel temperature extremely high M7974 Door open
M5815 Fuel temperature in shutdown M8402 DESOX service requested
M5826 Fuel temperature pre-shutdown M8450 DESOX regeneration needed - inhibit active
M5902 DPF regeneration switch error ON M8541 DPF automatic regeneration active
DPF automatic regeneration active (Operate
M6002 DPF inhibit regeneration switch error ON M8542
machine under load)
M6102 Remote parked regeneration switch error ON M8543 DPF regeneration required
M6202 Tailgate fan 1 error ON M8551 DPF regeneration needed – inhibit active
DPF regeneration needed – inhibit active
M6203 Tailgate fan 1 error OFF M8552
(Operate machine under load)
DPF remote parked regeneration required
M6228 Tailgate fan 1 Failure M8553
(Remote regeneration kit required)
DPF service regeneration required (Contact
M6302 Tailgate fan 2 error ON M8554
Bobcat dealer)
M6303 Tailgate fan 2 error OFF M8555 DPF service required
M6328 Tailgate fan 2 Failure M8560 DPF service regeneration active
M6402 Switched power relay error ON M8561 DPF service regeneration active
M6403 Switched power relay error OFF M8562 DPF service regeneration active
M6505 ECU power short to battery M8563 DPF service regeneration active
M6506 ECU power short to ground M8564 DPF service regeneration active
M6507 ECU power open circuit M8615 Engine speed derate in shutdown
M6604 ECU no communication M8625 Engine speed derate unresponsive
M6702 HVAC output error ON M8715 Torque derate in shutdown
M6703 HVAC output error OFF M8725 Torque derate unresponsive
M6707 HVAC output open circuit
M6728 HVAC output failure R7404 Main controller no communication
M6802 HVAC relay error ON
M6803 HVAC relay error OFF T9002 Service tool output ‘C’ error ON
M6904 DCU no communication T9003 Service tool output ‘C’ error OFF
M7002 Switched power output error ON T9102 Service tool output ‘D’ error ON
M7003 Switched power output error OFF T9103 Service tool output ‘D’ error OFF

713 of 1052 60-100-11 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

T9202 Service tool output ‘E’ error ON U00321919 NOX pre-treatment sensor fault
T9203 Service tool output ‘E’ error OFF U00322021 NOX pre-treatment sensor fault
T9302 Service tool output ‘F’ error ON U00322022 NOX post-treatment sensor fault
T9303 Service tool output ‘F’ error OFF U00322023 NOX pre-treatment sensor fault
U00015822 DCU activation signal fault U00322024 NOX post-treatment sensor fault
U00017100 Environment temperature too high U00322025 NOX pre-treatment sensor fault
U00017101 Environment temperature too low U00322026 NOX post-treatment sensor fault
U00017103 Environment temperature sensor fault U00322103 NOX pre-treatment sensor fault
U00017104 Environment temperature sensor fault U00322104 NOX pre-treatment sensor fault
U00044400 Battery voltage high U00322302 NOX pre-treatment sensor fault
U00044401 Battery voltage too low U00322400 NOX pre-treatment sensor fault
U00044402 Battery voltage fault U00322401 NOX pre-treatment sensor fault
U00054419 DCU communication fault U00322403 NOX pre-treatment sensor fault
U00063928 DCU communication fault U00322404 NOX pre-treatment sensor fault
U00063929 DCU communication fault U00322419 NOX pre-treatment sensor fault
U00155719 DCU communication fault U00322423 NOX pre-treatment sensor fault
U00176100 DEF level too high U00322519 NOX pre-treatment sensor fault
U00176101 DEF level too low U00322604 NOX post-treatment sensor short circuit
U00176115 DEF level extremely low U00322605 NOX post-treatment sensor open circuit
U00176116 DEF level empty U00322619 NOX post-treatment sensor fault
U00176119 DEF level signal fault U00322701 NOX post-treatment sensor fault
U00176120 DEF fill level fault U00322703 NOX post-treatment sensor fault
U00176121 DEF fill level fault U00322704 NOX post-treatment sensor fault
U00303100 DEF temperature too high U00322719 NOX post-treatment sensor fault
U00303101 DEF temperature too low U00322722 NOX post-treatment sensor fault
U00303103 DEF temperature fault U00322724 NOX post-treatment sensor fault
U00303104 DEF temperature fault U00322807 NOX post-treatment sensor fault
U00303120 DEF temperature fault U00322819 NOX post-treatment sensor fault
U00303121 DEF temperature fault U00322824 NOX post-treatment sensor fault
U00303123 DEF overheating U00322919 NOX post-treatment sensor fault
U00303127 DEF temperature sensor fault U00323103 NOX post-treatment sensor fault
U00303131 DEF temperature signal fault U00323104 NOX post-treatment sensor fault
U00321604 NOX pre-treatment sensor short circuit U00323302 NOX post-treatment sensor fault
U00321605 NOX pre-treatment sensor open circuit U00323400 NOX post-treatment sensor fault
U00321619 NOX pre-treatment sensor fault U00323401 NOX post-treatment sensor fault
U00321700 NOX pre-treatment sensor fault U00323403 NOX post-treatment sensor fault
U00321703 NOX pre-treatment sensor fault U00323404 NOX post-treatment sensor fault
U00321704 NOX pre-treatment sensor fault U00323419 NOX post-treatment sensor fault
U00321719 NOX pre-treatment sensor fault U00323424 NOX post-treatment sensor fault
U00321721 NOX pre-treatment sensor fault U00323519 NOX post-treatment sensor fault
U00321723 NOX pre-treatment sensor fault U00336103 Dosing valve short to battery
U00321807 NOX pre-treatment sensor fault U00336104 Dosing valve short to ground
U00321819 NOX pre-treatment sensor fault U00336105 Dosing valve short to battery
U00321823 NOX pre-treatment sensor fault U00336112 Dosing valve temperature too high

714 of 1052 60-100-12 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

U00336122 Dosing valve short to ground U00433712 Dosing valve tip temperature fault
U00336127 Dosing valve blocked U00433912 NOX controller fault
U00336303 DEF tank coolant valve short to battery U00434003 DEF line heater short to battery
DEF outlet line heater short to ground or open
U00336304 DEF tank coolant valve short to ground U00434205
circuit
U00336305 DEF tank coolant valve open circuit U00434402 Backflow fault
DEF backflow line heater short to ground or
U00336312 DEF tank coolant valve temperature too high U00434405
open circuit
DEF inlet line heater short to ground or open
U00349212 DCU fault U00434605
circuit
U00349231 DCU fault U00435303 DEF heater relay short to battery
U00350923 DCU fault U00435304 DEF heater relay short to ground
U00350924 DCU fault U00435305 DEF heater relay open circuit
U00351023 DCU fault U00435312 DEF heater relay overtemperature
U00351024 DCU fault U00435502 Outlet line heater fault
U00351123 DCU fault U00435503 Outlet line heater short to battery
U00351124 DCU fault U00435504 Outlet line heater short to ground
U00351223 DCU fault U00435505 Outlet line heater open circuit
U00351224 DCU fault U00435512 Outlet line heater overtemperature
U00351600 DEF quality too high U00435514 Outlet line heater fault
U00351601 DEF quality too low U00435602 Backflow line heater short to battery
U00351603 DEF quality sensor fault U00435603 Backflow line heater short to ground
U00351604 DEF quality sensor fault U00435604 Backflow line heater open circuit
U00351611 DEF quality sensor fault U00435605 Backflow line heater overtemperature
U00351631 DEF quality sensor fault U00435612 Backflow line heater fault
U00353203 DEF level sensor fault U00435702 Inlet line heater short to battery
U00353204 DEF level sensor fault U00435703 Inlet line heater short to ground
U00353211 DEF level sensor fault U00435704 Inlet line heater open circuit
U00431915 SCR post-treatment temperature fault U00435705 Inlet line heater overtemperature
U00431917 SCR post-treatment temperature fault U00435712 Inlet line heater fault
U00433401 DEF pump pressure too low U00436000 SCR pre-treatment temperature too high
U00433403 DEF pump pressure max U00436001 SCR pre-treatment temperature too low
SCR pre-treatment temperature sensor out of
U00433404 DEF pump pressure min U00436003
range high
SCR pre-treatment temperature sensor out of
U00433419 DEF pump pressure fault U00436004
range low
U00433420 DEF pump pressure too high U00436020 SCR pre-treatment temperature fault
U00433421 DEF pump pressure too low U00436021 SCR pre-treatment temperature fault
U00433422 Backflow pump fault U00436022 SCR pre-treatment temperature fault
SCR pre-treatment temperature sensor
U00433500 Metering control overpressure U00436025
tampering
U00433501 Metering control underpressure U00436300 SCR post-treatment temperature too high
U00433502 Monitoring of pressure buildup U00436301 SCR downstream temperature too low
SCR downstream temperature sensor out of
U00433512 Monitoring of overpressure U00436303
range high
SCR downstream temperature sensor out of
U00433707 Dosing valve tip temperature fault U00436304
range low

715 of 1052 60-100-13 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

U00436322 SCR post-treatment temperature fault U00503519 NOX post-treatment CAN communication fault
U00436325 SCR downstream temperature sensor tampering U00503619 NOX post-treatment CAN communication fault
U00436400 NOX pre-treatment fault U00503719 NOX post-treatment CAN communication fault
U00436401 NOX pre-treatment fault U00543510 Pressure stabilization fault
U00436416 SCR fault U00543512 General pressure check fault
U00436418 SCR fault U00543529 DEF pump motor fault
U00436420 SCR fault U00570622 Supply module heater fault
U00436421 SCR fault U00570623 Supply module heater fault
U00436422 SCR fault U00570624 Supply module heater fault
U00436423 SCR fault U00570626 Supply module heater temperature fault
U00436503 DEF temperature sensor open circuit U00570627 Supply module heater temperature fault
U00436504 DEF temperature sensor short to ground U00570703 Supply module heater short to battery
U00436511 DEF temperature sensor failure U00570704 Supply module heater short to ground
U00437423 DEF pump motor speed fault U00570705 Supply module heater open circuit
U00437424 DEF pump motor speed fault U00570712 Supply module heater overtemperature
U00437428 DEF pump motor speed fault U00570723 Supply module heater temperature duty high
U00437430 DEF pump motor speed fault U00570724 Supply module heater temperature duty low
U00437503 DEF pump motor short to battery U00570726 Supply module heater temperature fault
U00437504 DEF pump motor short to ground U00570727 Supply module heater temperature fault
U00437505 DEF pump motor open circuit U00571302 NOX sensor self diagnostics
U00437512 DEF pump motor overtemperature U00571307 NOX sensor self diagnostics
U00437523 DEF pump motor fault U00571319 NOX sensor self diagnostics
U00437524 DEF pump motor fault U00571402 NOX sensor self diagnostics
U00437603 DEF backflow pump short to battery U00571407 NOX sensor self diagnostics
U00437604 DEF backflow pump short to ground U00571419 NOX sensor self diagnostics
U00437605 DEF backflow pump open circuit U05990419 CAN communications fault
U00437612 DEF backflow pump overtemperature U06016019 CAN communications fault
U00476500 DOC pre-treatment temperature too high U06041619 CAN communications fault
U00476501 DOC pre-treatment temperature too low U06144419 CAN communications fault
DOC pre-treatment temperature sensor out of
U00476503 U06145419 CAN communications fault
range high
DOC pre-treatment temperature sensor out of
U00476504 U06145519 CAN communications fault
range low
U00502419 NOX pre-treatment CAN communication fault U06463919 Memory fault
U00502519 NOX pre-treatment CAN communication fault U06463931 Memory fault
U00502619 NOX pre-treatment CAN communication fault U06478219 CAN communications fault
U00502719 NOX pre-treatment CAN communication fault U06478319 CAN communications fault
U00502819 NOX pre-treatment CAN communication fault U06478419 CAN communications fault
U00502919 NOX pre-treatment CAN communication fault U06478519 CAN communications fault
U00503019 NOX pre-treatment CAN communication fault U06480019 CAN communications fault
U00503119 NOX post-treatment CAN communication fault U06481719 CAN communications fault
U00503219 NOX post-treatment CAN communication fault U06488919 CAN communications fault
U00503319 NOX post-treatment CAN communication fault U06491619 CAN communications fault
U00503419 NOX post-treatment CAN communication fault U06492319 CAN communications fault

716 of 1052 60-100-14 T870 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE DESCRIPTION CODE DESCRIPTION

U06516419 CAN communications fault W3232 ACS (AHC) tilt actuator wiring
U06522619 CAN communications fault W3233 ACS (AHC) tilt handle wiring
U06522621 CAN communications fault W3234 ACS (AHC) tilt actuator not in NEUTRAL
U06522622 CAN communications fault W3235 ACS (AHC) tilt handle / pedal not in NEUTRAL
U06522623 CAN communications fault W3236 ACS (AHC) lift actuator
U06522624 CAN communications fault W3237 ACS (AHC) lift actuator wiring
U06522625 CAN communications fault W3238 ACS (AHC) lift handle wiring
U06524719 CAN communications fault W3239 ACS (AHC) lift actuator not in NEUTRAL
U06526219 CAN communications fault W3240 ACS (AHC) lift handle / pedal not in NEUTRAL
U06526919 CAN communications fault W3241 ACS (AHC) no communication
U06527019 CAN communications fault W3249 ACS (AHC) lift actuator short to ground
U06529619 CAN communications fault W3250 ACS (AHC) tilt actuator short to ground
U06530019 CAN communications fault W3251 ACS (AHC) lift actuator short to battery
U10123907 DEF hose leak W3252 ACS (AHC) tilt actuator short to battery
U10124007 Evaluate filter clog W3253 ACS (AHC) lift handle / pedal short to ground
U10433207 NOX pre-treatment fault W3254 ACS (AHC) tilt handle / pedal short to ground
U10433209 NOX pre-treatment fault W3255 ACS (AHC) lift handle / pedal short to battery
U10433219 NOX pre-treatment fault W3256 ACS (AHC) tilt handle / pedal short to battery
U10433221 NOX pre-treatment fault W3257 ACS (AHC) lift actuator reduced performance
U10433223 NOX pre-treatment fault W3258 ACS (AHC) tilt actuator reduced performance
U10433224 NOX pre-treatment fault W3259 ACS (AHC) lift actuator wrong direction
U10438507 NOX post-treatment fault W3260 ACS (AHC) tilt actuator wrong direction
U10438509 NOX post-treatment fault W3261 ACS (AHC) handle lock short to ground
U10438519 NOX post-treatment fault W3262 ACS (AHC) handle lock short to battery
U10438522 NOX post-treatment fault W3263 ACS (AHC) pedal lock short to ground
U10564413 DCU fault W3264 ACS (AHC) pedal lock short to battery
U10564513 DCU fault W3265 ACS (AHC) sensor supply voltage out of range
U10564613 DCU fault W3266 ACS (AHC) battery voltage out of range
U52020212 DCU fault W3267 ACS (AHC) switch flipped while operating
U52020412 DCU fault W3268 ACS (AHC) lift handle information error
ACS (AHC) control mode toggle switched while
U52069812 DCU fault W3269
operating
U52069912 DCU fault W3270 ACS (AHC) right drive handle short to ground
U52070012 DCU fault W3271 ACS (AHC) right drive handle short to battery
U52070112 DCU fault W3274 ACS (AHC) left joystick X-axis out of range
U52160212 DCU sensor supply error W3275 ACS (AHC) interrupted unswitched power
W3276 ACS (AHC) CAN joystick information error
ACS (AHC) no communication to Bobcat
W3204 W3277 ACS (AHC) remote control information error
controller
W3223 ACS (AHC) calibration required W3297 ACS (AHC) controller programmed
W3224 ACS (AHC) calibration performed W3905 Left joystick X-axis not in NEUTRAL
W3225 ACS (AHC) actuator calibration failed W4005 Right joystick X-axis not in NEUTRAL
W3231 ACS (AHC) tilt actuator W4007 Right joystick Y-axis not in NEUTRAL

717 of 1052 60-100-15 T870 Service Manual

718 of 1052 60-100-16 T870 Service Manual
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

Description

Figure 60-110-1

1 2 3

4
3
P-85413F

The Bobcat Interlock Control System is an electronic

system that is used to protect the operator. The system
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 60-110-1] of the loader cab.

The Press To Operate button (Item 4) [Figure 60-110-1]

activates the system and allows the operator to function
the loader.

719 of 1052 60-110-1 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)
See the SERVICE SCHEDULE for the correct service slowly forward and backward. The TRACTION lock
interval. (See SERVICE SCHEDULE on Page 10-70-1.) must be engaged. Lower the seat bar. Press the
PRESS TO OPERATE LOADER button.
Figure 60-110-2
7. Engage parking brake and move steering handles or
1 joystick(s) slowly forward and backward. The
2 3
TRACTION lock must be engaged.

NOTE: The PARKING BRAKE light on the left

instrument panel will remain ON until the
engine is started, the PRESS TO OPERATE
4 LOADER button is pressed and the parking
brake is disengaged.

Inspecting The Lift Arm Bypass Control

5
8. Raise the lift arms 2 m (6 ft) off the ground. Stop
6 engine. Turn lift arm bypass control knob 90°
P-85413F clockwise. Pull up and hold lift arm bypass control
knob until lift arms slowly lower.
1. Sit in operator’s seat. Turn key switch to RUN. Lower
Inspecting Deactivation Of Lift And Tilt Functions
seat bar and disengage parking brake. Press the
(SJC)
PRESS TO OPERATE LOADER button (Item 6). Two
BICS™ lights (Items 1 and 2) [Figure 60-110-2]
9. Sit in operator’s seat and fasten seat belt. Lower seat
[SEAT BAR and LIFT AND TILT VALVE] on left
bar, start engine and press the PRESS TO OPERATE
instrument panel must be OFF. The PRESS TO
LOADER button.
OPERATE LOADER button will light.
10. Raise lift arms about 2 m (6 ft) off the ground.
2. Raise seat bar fully. All three BICS™ lights (Items 1,
2 and 3) [Figure 60-110-2] [SEAT BAR, LIFT AND
11. Turn key switch to stop and wait for the engine to
TILT VALVE and PARKING BRAKE] on left
come to a complete stop.
instrument panel must be ON. The PRESS TO
OPERATE LOADER button light will turn OFF.
12. Turn key switch to RUN. Press the PRESS TO
OPERATE LOADER button, move the joystick to
Inspecting Deactivation Of The Auxiliary Hydraulics
lower the lift arms. Lift arms must not lower.
System (Engine STOPPED - Key ON)
13. Move the joystick to tilt the bucket (or attachment)
3. Sit in operator’s seat, lower seat bar and press the
forward. The bucket (or attachment) must not tilt
PRESS TO OPERATE LOADER button (Item 6).
forward.
Press the auxiliary hydraulics button (Item 5). The
auxiliary hydraulics light will be ON (Item 4) [Figure
60-110-2]. Raise the seat bar. The light must be OFF.

Inspecting The Seat Bar Sensor (Engine RUNNING) WARNING

4. Sit in operator’s seat, lower seat bar, engage parking
brake and fasten seat belt. AVOID INJURY OR DEATH
The Bobcat Interlock Control System (BICS™) must
5. Start engine and operate at low idle. Press the deactivate the lift, tilt and traction drive functions. If it
PRESS TO OPERATE LOADER button. While raising does not, contact your dealer for service. DO NOT
the lift arms, raise the seat bar fully. The lift arms must modify the system.
stop. Repeat using the tilt function. W-2151-1111

720 of 1052 60-110-2 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. Check for codes. Refer to BATS for description
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.
4. Use seat bar sensor tester MEL1428 to isolate problem between sensor and controller and wiring.
5. Possible low or high voltage.

721 of 1052 60-110-3 T870 Service Manual

722 of 1052 60-110-4 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.
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.

723 of 1052 60-120-1 T870 Service Manual

SEAT BAR SENSOR (CONT'D) Figure 60-120-3

Testing

Use Sensor Tester (MEL1428) and Seat Bar Sensor

Adapter (MEL1567) for the following procedure:

Connect the Seat Bar Sensor Adapter leads (MEL1567)

to the Sensor Tester.
2
Figure 60-120-1

P-4698

If there is no power light (Item 1) [Figure 60-120-3] on

the Sensor Tester, check the tester or wiring harness.
1
Figure 60-120-4

P-85653

1
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-120-1].

Figure 60-120-2

P-4699

Lower the seat bar. The Sensor Test light (Item 1)

1 [Figure 60-120-4] should illuminate.

Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-120-4] 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 60-120-2]
inline, to the seat bar sensor connectors. [Figure 60-120- Replace the Seat Bar Sensor. (See Removal And
2]. Installation on Page 60-120-3.)

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 60-120-6.)
The toggle switch (Item 2) [Figure 60-120-3] can be in
either the Absent or Present position.

724 of 1052 60-120-2 T870 Service Manual

SEAT BAR SENSOR (CONT'D) Figure 60-120-7

Removal And Installation

NOTE: This procedure is performed with the seat bar

in the raised position and the technician in the 3
operator’s seat.

Figure 60-120-5

1 2

P100745

Remove the retaining pin (Item 1) and clevis pin (Item 2)

[Figure 60-120-7]. Remove the seat bar mounting bolt
and nut (Item 3) [Figure 60-120-7].
2

P100742

Remove the sensor mounting bolt and nut (Item 1)

[Figure 60-120-5]. Disconnect the sensor wiring
connector (Item 2) [Figure 60-120-5].

Figure 60-120-6

P100743
P100759

Tighten the clevis bolt (Item 1) until spring tension is

released from the clevis pin (Item 2) [Figure 60-120-6].
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.

725 of 1052 60-120-3 T870 Service Manual

SEAT BAR SENSOR (CONT'D) Figure 60-120-10

Removal And Installation (Cont’d)

3
Figure 60-120-8
2

1
4

P100748

Install the new keyed bushing (Item 1), magnet bushing

P100746
(Item 2) and seat bar sensor (Item 3) [Figure 60-120-10].
Reinstall the metal pivot bushing (Item 4) and the bolt
Pull the front of the seat bar down slightly from the top of (Item 5) [Figure 60-120-10].
the cab, while raising the sensor end of the seat bar up,
away from the mount [Figure 60-120-8]. NOTE: The sensor must be centered on the metal
pivot bushing. When centered, the assembly
NOTE: The sensor end of the seat bar will raise easily will slide freely into the mount.
ONLY if the front of the seat bar is pulled
slightly down from the top of the cab. Figure 60-120-11

Figure 60-120-9

4 3
1
3

6 1
2

P100749

2
P100747
Position the clevis (Item 1) over the mount (Item 2) and
lower the end of the seat bar until the mounting bolt (Item
Place a soft jaw locking pliers (Item 1) [Figure 60-120-9]
3) [Figure 60-120-11] is resting on the top of the mount.
on the cab side screen to hold the seat bar above the
mount.
Remove the nut from the mounting bolt. Remove the
Remove the clevis pin bushing (Item 2) [Figure 60-120- mounting bolt and lower the seat bar until the seat bar
9]. Apply grease to the shoulder of the bushing to help and mount holes align and the clevis is over the clevis pin
retain it during assembly. Reinstall the clevis pin bushing. bushing. Reinstall the seat bar mounting bolt. Apply
Loctite® 243 to the nut threads. Install the nut and tighten
Remove and dispose of the keyed bushing (Item 3), to 46 N•m (34 ft-lb) torque.
magnet bushing (Item 4), and seat bar sensor (Item 5)
[Figure 60-120-9].

Remove and save the metal pivot bushing (Item 6)

[Figure 60-120-9].

726 of 1052 60-120-4 T870 Service Manual

SEAT BAR SENSOR (CONT'D)

Removal And Installation (Cont’d)

Figure 60-120-12

1
2

P100751 3
P100759

Reinstall the clevis pin (Item 1), and retaining pin (Item 2)
[Figure 60-120-12].

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

60-120-5].

Reinstall the sensor mounting bolt and nut (Item 1)

[Figure 60-120-5] 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.

727 of 1052 60-120-5 T870 Service Manual

SEAT BAR SENSOR (CONT'D) Figure 60-120-14

Bobcat Interlock Control System (BICS™) Circuit

Test

Use Sensor Tester (MEL1428) and Seat Bar Sensor

3
Adapter (MEL1567) for the following procedure:

Connect the Seat Bar Sensor Adapter leads (MEL1567)

to the Sensor Tester. 2

Figure 60-120-13
1

P-4703

Connect Sensor Tester (Item 1) [Figure 60-120-14] inline

to the seat bar sensor connectors.

1 Turn the key to the ON position. DO NOT START THE

ENGINE.

If the above test fails, there is a problem with the seat bar
sensor or with the sensor harness.
P-85653
When the power light is illuminated, move the toggle
switch (Item 2) [Figure 60-120-14] on the Sensor Tester
Disconnect the seat bar sensor connector (Item 1) to the Present position.
[Figure 60-120-13].
NOTE: The Sensor Test light (Item 3) [Figure 60-120-
14] is only activated by the seat bar. It will be
off with the seat bar up or on with the seat bar
down.

728 of 1052 60-120-6 T870 Service Manual

SEAT BAR SENSOR (CONT'D)

Bobcat Interlock Control System (BICS™) Circuit

Test (Cont’d)

Figure 60-120-15

P-85413F

The BICS™ seat bar indicator light (Item 1) [Figure 60-

120-15] should turn OFF.

Figure 60-120-16

P-4699

Move the toggle switch (Item 1) [Figure 60-120-16] on

the sensor tester to the Absent position.

The Seat Bar light (Item 1) [Figure 60-120-15] should

illuminate.

If the above test fails, there is a problem with the Bobcat

Controller or the wiring harness.

729 of 1052 60-120-7 T870 Service Manual

730 of 1052 60-120-8 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™).

731 of 1052 60-130-1 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.
6. Check for loose or pushed back bent pins in connectors.
7. Check the left panel display for engine rpm, if no rpm check crankshaft sensor, camshaft sensor, wiring and
adjustment.

732 of 1052 60-130-2 T870 Service Manual

TRACTION LOCK (CONT'D)

Inspecting

Figure 60-130-1

1
P-85413F

Sit in operator’s seat, lower seat bar, engage parking

brake and fasten seat belt.

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 60-130-1].

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.

733 of 1052 60-130-3 T870 Service Manual

734 of 1052 60-130-4 T870 Service Manual
ELECTRICAL / HYDRAULIC CONTROLS (SJC)

Identification Chart

1 2 3 4 5 13 14 15 16 17
11 11
8
8

9
10
9
10 18
6 7 19
12 12 B-19873A / NA5719 / B-19874A

REF. NO. DESCRIPTION

1 TWO-SPEED CONTROL 
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

735 of 1052 60-140-1 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

for more detailed information.

736 of 1052 60-140-2 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
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 ELECTRICAL / 2
1
HYDRAULIC CONTROLS (SJC) on Page 60- 7
140-1.) 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 NA1892

moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3, 4, 5, and 6 at the diverter Solenoid Hydraulic Coupler Wiring
valve. Number Number
1 Front Male (Rod) 4330
Front Auxiliary Pressure Release is 2 Front Female (Base) 4340
accomplished by manually pushing the male 3 Diverter Rear (Rod) 4430
and female couplers in at the front auxiliary
4 Diverter Rear (Base) 4440
block.
5 Bleed / Lock Valve (Base) 4480
The High Flow Button in the left side 6 Bleed / Lock Valve (Rod) 4450
instrument panel must be pushed ON to 7 High Flow on Pump 4460
activate solenoid number seven at the gear
pump.

737 of 1052 60-140-3 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
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 ELECTRICAL / 2
1
HYDRAULIC CONTROLS (SJC) on Page 60- 7
140-1.) 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 NA1892

moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3, 4, 5, and 6 at the diverter Solenoid Hydraulic Coupler Wiring
valve. Number Number
1 Front Male (Rod) 4330
Front Auxiliary Pressure Release is 2 Front Female (Base) 4340
accomplished by manually pushing the male 3 Diverter Rear (Rod) 4430
and female couplers in at the front auxiliary
4 Diverter Rear (Base) 4440
block.
5 Bleed / Lock Valve (Base) 4480
The High Flow Button in the left side 6 Bleed / Lock Valve (Rod) 4450
instrument panel must be pushed ON to 7 High Flow on Pump 4460
activate solenoid number seven at the gear
pump.

738 of 1052 60-140-4 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
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 ELECTRICAL / 2
1
HYDRAULIC CONTROLS (SJC) on Page 60- 7
140-1.) 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 NA1892

moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3, 4, 5, and 6 at the diverter Solenoid Hydraulic Coupler Wiring
valve. Number Number
1 Front Male (Rod) 4330
Front Auxiliary Pressure Release is 2 Front Female (Base) 4340
accomplished by manually pushing the male 3 Diverter Rear (Rod) 4430
and female couplers in at the front auxiliary
4 Diverter Rear (Base) 4440
block.
5 Bleed / Lock Valve (Base) 4480
The High Flow Button in the left side 6 Bleed / Lock Valve (Rod) 4450
instrument panel must be pushed ON to 7 High Flow on Pump 4460
activate solenoid number seven at the gear
pump.

739 of 1052 60-140-5 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
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 ELECTRICAL / 2
1
HYDRAULIC CONTROLS (SJC) on Page 60- 7
140-1.) 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 NA1892

moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3, 4, 5, and 6 at the diverter Solenoid Hydraulic Coupler Wiring
valve. Number Number
1 Front Male (Rod) 4330
Front Auxiliary Pressure Release is 2 Front Female (Base) 4340
accomplished by manually pushing the male 3 Diverter Rear (Rod) 4430
and female couplers in at the front auxiliary
4 Diverter Rear (Base) 4440
block.
5 Bleed / Lock Valve (Base) 4480
The High Flow Button in the left side 6 Bleed / Lock Valve (Rod) 4450
instrument panel must be pushed ON to 7 High Flow on Pump 4460
activate solenoid number seven at the gear
pump.

740 of 1052 60-140-6 T870 Service Manual

ELECTRICAL / HYDRAULIC CONTROLS (SCPA)

Identification Chart

1 2 3 4 5 13 14 15 16 17
8

10 11
18
6 7 19
12
NA3108 / NA5720 /NA3109A

REF. NO. DESCRIPTION

1 TWO-SPEED CONTROL 
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 ENGINE SPEED CONTROL (HAND OPERATED)
9 STEERING HANDLES
10 LIFT ARM PEDAL
11 TILT PEDAL
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

741 of 1052 60-141-1 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

for more detailed information.

742 of 1052 60-141-2 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
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 ELECTRICAL / 2
1
HYDRAULIC CONTROLS (SJC) on Page 60- 7
140-1.) 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 NA1892

moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3, 4, 5, and 6 at the diverter Solenoid Hydraulic Coupler Wiring
valve. Number Number
1 Front Male (Rod) 4330
Front Auxiliary Pressure Release is 2 Front Female (Base) 4340
accomplished by manually pushing the male 3 Diverter Rear (Rod) 4430
and female couplers in at the front auxiliary
4 Diverter Rear (Base) 4440
block.
5 Bleed / Lock Valve (Base) 4480
The High Flow Button in the left side 6 Bleed / Lock Valve (Rod) 4450
instrument panel must be pushed ON to 7 High Flow on Pump 4460
activate solenoid number seven at the gear
pump.

743 of 1052 60-141-3 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
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 ELECTRICAL / 2
1
HYDRAULIC CONTROLS (SJC) on Page 60- 7
140-1.) 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 NA1892

moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3, 4, 5, and 6 at the diverter Solenoid Hydraulic Coupler Wiring
valve. Number Number
1 Front Male (Rod) 4330
Front Auxiliary Pressure Release is 2 Front Female (Base) 4340
accomplished by manually pushing the male 3 Diverter Rear (Rod) 4430
and female couplers in at the front auxiliary
4 Diverter Rear (Base) 4440
block.
5 Bleed / Lock Valve (Base) 4480
The High Flow Button in the left side 6 Bleed / Lock Valve (Rod) 4450
instrument panel must be pushed ON to 7 High Flow on Pump 4460
activate solenoid number seven at the gear
pump.

744 of 1052 60-141-4 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
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 ELECTRICAL / 2
1
HYDRAULIC CONTROLS (SJC) on Page 60- 7
140-1.) 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 NA1892

moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3, 4, 5, and 6 at the diverter Solenoid Hydraulic Coupler Wiring
valve. Number Number
1 Front Male (Rod) 4330
Front Auxiliary Pressure Release is 2 Front Female (Base) 4340
accomplished by manually pushing the male 3 Diverter Rear (Rod) 4430
and female couplers in at the front auxiliary
4 Diverter Rear (Base) 4440
block.
5 Bleed / Lock Valve (Base) 4480
The High Flow Button in the left side 6 Bleed / Lock Valve (Rod) 4450
instrument panel must be pushed ON to 7 High Flow on Pump 4460
activate solenoid number seven at the gear
pump.

745 of 1052 60-141-5 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
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 ELECTRICAL / 2
1
HYDRAULIC CONTROLS (SJC) on Page 60- 7
140-1.) 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 NA1892

moving the rear auxiliary hydraulic switch to
the right and left several times activates
solenoid numbers 3, 4, 5, and 6 at the diverter Solenoid Hydraulic Coupler Wiring
valve. Number Number
1 Front Male (Rod) 4330
Front Auxiliary Pressure Release is 2 Front Female (Base) 4340
accomplished by manually pushing the male 3 Diverter Rear (Rod) 4430
and female couplers in at the front auxiliary
4 Diverter Rear (Base) 4440
block.
5 Bleed / Lock Valve (Base) 4480
The High Flow Button in the left side 6 Bleed / Lock Valve (Rod) 4450
instrument panel must be pushed ON to 7 High Flow on Pump 4460
activate solenoid number seven at the gear
pump.

746 of 1052 60-141-6 T870 Service Manual

SERVICE PC (LAPTOP COMPUTER) Connecting Remote Start Tool (Service Tool)

Connecting Remote Start Tool 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: 7217666 - Remote Start
Tool (Service Tool) Kit
MEL1563 - Remote Start Tool Kit
MEL1566 - Service Tool Harness Communicator Kit Includes:
(Computer Interface)
7022042 - Remote Start Tool (Service Tool)
Figure 60-150-1 6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
1 2 6689745 - BOSS® Service Tool Harness

Figure 60-150-2

P16119

3
The Service PC (Item 1) with the Remote Start Tool (Item 1
2) [Figure 60-150-1]. When connected to the loader, the
P-76450
Service PC is used to monitor, conduct diagnostics, and
upgrade software.
The Service PC (Item 1) with the Remote Start Tool
NOTE: Make all connections with the key in the OFF (Service Tool) (Item 2) [Figure 60-150-2]. When
position. connected to the loader, the Service PC is used to
monitor, conduct diagnostics, and upgrade software.
Connect the Service Tool Harness Communicator
(MEL1566) (Item 3) [Figure 60-150-1] to the designated NOTE: Make all connections with the key in the OFF
serial port on the Service PC. position.

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 60-150-2] 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 - 7217666 on Page 10-61-1.)

747 of 1052 60-150-1 T870 Service Manual

748 of 1052 60-150-2 T870 Service Manual
CALIBRATION Actuator Testing

Description NOTE: The Actuator Test calibrates the lift and tilt
system therefore no further lift and tilt
Calibration procedures must be followed when replacing calibration is required if using this method.
a hydraulic control valve, actuator, Drive/Drive+
Controller, ACS Controller, pump controller, hydrostatic Figure 60-160-1
pump, or hydrostatic motor. Failure to calibrate after
CONTROL VALVE ACTUATORS
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.

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
and Tilt Calibration (SJC) should be used if reduced P107847A
performance codes are present or when replacing a
controller or actuator.
[Figure 60-160-1] Excessive actuator loading can occur
NOTE: The Actuator Test should be used as the if the actuator and valve spool components are
preferred method of lift and tilt calibration. misaligned. Misalignment may reduce spool stroke
performance and reduce the life of the actuator.
The Hydrostatic Pump Calibration (SJC / SCPA) provides
set points to the Drive controller to actuate the Connect the Service PC. (See SEAT BAR SENSOR on
hydrostatic controller that directs flow to a servo piston. Page 60-120-1.)
Hydrostatic Pump Calibration (SJC / SCPA) should be
performed when a desired travel path cannot be attained If a Service PC is not available, (See Lift And Tilt
or replacing the hydrostatic pump, hydrostatic motor, or Calibration (SJC) on Page 60-160-4.)
controller. After Performing a Hydrostatic Pump
Calibration (SJC / SCPA), Steering Drift Compensation NOTE: Warm the hydraulic oil to room temperature
can be used to fine tune the hydrostatic pump control. 22°C (72°F), stop the engine and clear all
active service codes before running the test.
For more information on Steering Drift Compensation.
(See CALIBRATION on Page 60-160-1.) Once the test is initiated, an automatic calibration
sequence will start. When calibration is complete, the test
will be performed and the results can be viewed on the
Service PC monitor.

749 of 1052 60-160-1 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 to 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 following probable causes in Column 1 [Figure 60-160-
allow the centering springs to return the spools to 2]. Check the probable causes in the order they are
NEUTRAL. listed. Repairing one cause may be all that is required.
Re-run the test to verify.
When complete, the Actuator Test will show a pass mode
or fail mode. The pass mode indicates that no problems NOTE: Actuator and spool misalignment. Re-tighten
were detected. The fail mode indicates one or a the two bolts evenly, turn the first bolt one
combination of three problems below. turn, then turn the other bolt one turn until
both bolts are tight.
• Actuator slow return to NEUTRAL. The spool returns
to NEUTRAL too slowly. If the Actuator Test failed due to a slow return to
NEUTRAL after checking the probable causes in Column
• Actuator did not fully extend / retract. During the test, 1 [Figure 60-160-2], check the following probable causes
the spool was not able to fully stroke in both in Column 2 [Figure 60-160-2].
directions.
• Contamination in the spool.
• Actuator out of NEUTRAL. The spool did not return to
the NEUTRAL window during the test. • The spool end cap may be loose, damaged or the
centering spring may be broken. Inspect the end cap
NOTE: A time out will occur if the test cannot be and the centering spring, replace if necessary.
completed within 8 seconds. If this happens,
retry the test. • The wire harness or connectors may have an
intermittent short. Check the connections and wire
Figure 60-160-2 harnesses.
Run Actuator Test
• The controller may be malfunctioning, replace the
controller.
Pass Fail

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 60-160-2] 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.

750 of 1052 60-160-2 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.

• 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.

751 of 1052 60-160-3 T870 Service Manual

CALIBRATION (CONT’D) Figure 60-160-4

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 60-160-1.)

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 60-160-4] and hold in position.

Figure 60-160-3

SJC

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

60-160-3] in the ISO position.

752 of 1052 60-160-4 T870 Service Manual

CALIBRATION (CONT’D) Figure 60-160-7

Lift And Tilt Calibration (SJC) (Cont’d)

Figure 60-160-5

P-85413F

P-85493A

At the left panel, press the PRESS TO OPERATE Button

With the seat bar down, turn the key switch ON [Figure (Item 1) [Figure 60-160-7] while holding the right joystick
60-160-5]. in position.

NOTE: Do not start the engine. Release the joystick.

Figure 60-160-6 NOTE: During the calibration cycle, the system will
beep. Once the calibration is complete, code
SJC W3224 (Calibration Successful) or W3225
(Calibration Failure) 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-

160-6] will start flashing and will continue to flash until the
calibration procedure is completed.

753 of 1052 60-160-5 T870 Service Manual

CALIBRATION (CONT’D) Figure 60-160-9

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

NOTE: If swash plate sensors have been removed

With the seat bar down, turn the key switch ON [Figure
and reinstalled, replaced or adjusted the drive
60-160-9].
calibration procedure must be performed.
NOTE: Do not start the engine.
Place the loader on jack stands. (See Procedure on Page
10-10-1.)
Figure 60-160-10
Operator must be in the seat and the seat bar down. SJC

Figure 60-160-8

SJC

P-85307
1

The Control Pattern ISO Switch (Item 1) [Figure 60-160-

P-85307 10] will start flashing.

Close the cab door (If equipped).

Place the loader Control Pattern Switch (Item 1) [Figure

60-160-8] in the ISO position.

Verify that the parking brake switch is in the OFF position.

754 of 1052 60-160-6 T870 Service Manual

CALIBRATION (CONT'D) Figure 60-160-13

Hydrostatic Pump Calibration (SJC) (Cont'd)

Figure 60-160-11

B-19873

P-85960

B-19873 Move the left joystick to the reverse-right corner position

P-85959 [Figure 60-160-13] and hold in position.

Figure 60-160-14
Move the left joystick to the forward-left corner position
[Figure 60-160-11] and hold in position.

Figure 60-160-12

P-85413F

1
Press the PRESS TO OPERATE LOADER Button (Item
P-85413F 1) [Figure 60-160-14] while holding the left joystick in
position.

Press the PRESS TO OPERATE LOADER Button (Item Audible beeps will sound, release handle.
1) [Figure 60-160-12] while holding the left joystick in
position.

Audible beeps will sound, release handle.

755 of 1052 60-160-7 T870 Service Manual

CALIBRATION (CONT'D) Figure 60-160-17

Hydrostatic Pump Calibration (SJC) (Cont'd) SJC

Figure 60-160-15

P-85307

The Control Pattern ISO Switch (Item 1) [Figure 60-160-

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 60-160-18

[Figure 60-160-15].

Figure 60-160-16

P107184
1

P-85413F Move the engine speed control (Item 1) [Figure 60-160-

18] to high idle.

Press the PRESS TO OPERATE LOADER Button (Item NOTE: If at any time, during calibration, the operator
1) [Figure 60-160-16]. needs to stop the loader, turn the key OFF, lift
the seat bar, or return the joystick to the
Audible beeps will sound. NEUTRAL position.

Start the engine from the RUN position. DO NOT TURN The calibration procedure will stop.
TO OFF POSITION. This would cancel the calibration
mode and the procedure would have to be repeated. To return to calibration mode, the operator
must start the complete procedure from the
beginning.

756 of 1052 60-160-8 T870 Service Manual

CALIBRATION (CONT'D) Figure 60-160-20

Hydrostatic Pump Calibration (SJC) (Cont'd)

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

Figure 60-160-19 NA5744

The loader tires or tracks will momentarily reverse then

rotate forward and “stair step” the speed (Item 1) [Figure
60-160-20] until it reaches full speed and then “stair step”
down and 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
audible beep is heard.

Forward calibration is complete.

B-19873 NOTE: If the wheels or tracks do not stop moving in

P-85962 Full Speed Forward in 2 minutes or less, there
was an error in the calibration procedure. The
operator must shut the loader OFF, and start
Move and hold the left joystick to the forward position the calibration procedure from the beginning.
[Figure 60-160-19] until the forward calibration is
completed.

757 of 1052 60-160-9 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 60-160-21 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 60-160-19]
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 60-160-21] until the reverse calibration is 160-21] and check for normal reverse wheel or track
completed. rotation.
Figure 60-160-22 Stop the engine, and remove the loader from jackstands.

The calibration procedure is completed.

1
After calibration is complete, use Steering Drift
Compensation for fine tuning or if an acceptable line of
drift cannot be achieved. (See CALIBRATION on Page
60-160-1.)

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.)

NA5744

The loader tires or tracks will momentarily reverse then

continue to rotate in reverse and “stair step” the speed
(Item 1) [Figure 60-160-22] until it reaches full speed
and then “stair step” down and 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.

758 of 1052 60-160-10 T870 Service Manual

CALIBRATION (CONT’D) Figure 60-160-24

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

NOTE: If swash plate sensors have been removed

With the seat bar down, turn the key switch ON [Figure
and reinstalled, replaced or adjusted the drive
60-160-24].
calibration procedure must be performed.
NOTE: Do not start the engine.
Place the loader on jack stands. (See Procedure on Page
10-10-1.)
Figure 60-160-25
Operator must be in the seat and the seat bar down.

Figure 60-160-23

P-85959
1
Move the left steering handle to the forward position
P-90668E [Figure 60-160-25] and hold in position.

Close the cab door. (If equipped.)

Verify that the parking brake switch (Item 1) [Figure 60-

160-23] is in the OFF position.

759 of 1052 60-160-11 T870 Service Manual

CALIBRATION (CONT'D) Figure 60-160-28

Hydrostatic Pump Calibration (SCPA) (Cont'd)

Figure 60-160-26

P-85413F

1
Press the PRESS TO OPERATE LOADER Button (Item
P-85413F 1) [Figure 60-160-28] while holding the right steering
handle in position.

Press the PRESS TO OPERATE LOADER Button (Item Audible beeps will sound, release handle.
1) [Figure 60-160-26] while holding the left steering
handle in position.

Audible beeps will sound, release handle.

Figure 60-160-27

P100803

Move the right steering handle to the reverse position

[Figure 60-160-27] and hold in position.

760 of 1052 60-160-12 T870 Service Manual

CALIBRATION (CONT'D) Figure 60-160-31

Hydrostatic Pump Calibration (SCPA) (Cont'd)

Figure 60-160-29

P107184

Move the engine speed control (Item 1) [Figure 60-160-

P-85961 31] to high idle.

NOTE: If at any time, during calibration, the operator

Allow the steering handles to go to the NEUTRAL needs to stop the loader, turn the key OFF, lift
position [Figure 60-160-29]. the seat bar, or return the steering handle to
the NEUTRAL position.
Figure 60-160-30
The calibration procedure will stop.

To return to calibration mode, the operator

must start the complete procedure from the
beginning.

P-85413F

Press the PRESS TO OPERATE LOADER Button (Item

1) [Figure 60-160-30].

Audible beeps will sound.

Start the engine from the RUN position. DO NOT TURN

TO OFF POSITION. This would cancel the calibration
mode and the procedure would have to be repeated.

761 of 1052 60-160-13 T870 Service Manual

CALIBRATION (CONT'D) Figure 60-160-33

Hydrostatic Pump Calibration (SCPA) (Cont'd)

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

Figure 60-160-32 NA5744

The loader tires or tracks will momentarily reverse then

rotate forward and “stair step” the speed (Item 1) [Figure
60-160-33] until it reaches full speed and then “stair step”
down and 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
and an audible beep is heard.

Forward calibration is complete.

B-19873 NOTE: If the wheels or tracks do not stop moving in

P-85962 Full Speed Forward in 2 minutes or less, there
was an error in the calibration procedure. The
operator must shut the loader OFF, and start
Move and hold the left steering handle to the forward the calibration procedure from the beginning.
position [Figure 60-160-32] until the forward calibration
is completed.

762 of 1052 60-160-14 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 60-160-34 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-
160-32] and check for normal forward wheel or track
rotation.
Move and hold the left steering handle to the reverse
position [Figure 60-160-34] until the reverse calibration Move the left steering handle to the reverse position
is completed. [Figure 60-160-34] and check for normal reverse wheel
or track rotation.
Figure 60-160-35
Stop the engine, and remove the loader from jackstands.

1 The calibration procedure is completed.

After calibration is complete, use Steering Drift

Compensation for fine tuning or if an acceptable line of
drift cannot be achieved. (See CALIBRATION on Page
60-160-1.)

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.)
NA5744

The loader tires or tracks will momentarily reverse then

continue to rotate in reverse and “stair step” the speed
(Item 1) [Figure 60-160-35] until it reaches full speed
and then “stair step” down and 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.

763 of 1052 60-160-15 T870 Service Manual

764 of 1052 60-160-16 T870 Service Manual
STEERING DRIFT COMPENSATION (OPERATOR Operation
MODE)
Perform PRE-STARTING PROCEDURE and STARTING
Description THE ENGINE procedures:

Steering Drift Compensation can be used to reduce 1. Fasten seat belt.

steering drift to maintain a desired travel path in forward
and reverse directions. 2. Lower seat bar.

Examples of applications where this feature can be used: 3. Put controls in NEUTRAL position.

• To compensate for normal variations such as track 4. Start the engine.

tension and track wear.
5. Press the PRESS TO OPERATE LOADER button.
• Using side shift attachments such as trenchers,
planers, and silt fence installers. 6. Current drive response setting is displayed briefly in
the data display.
• Driving on uneven terrain such as crowned road
surfaces.

Figure 60-170-1

Steering Drift Compensation

NA3232

Steering drift compensation contains a total of 21

settings. Steering drift compensation can be set to any
point from NEUTRAL to [SFL10] or [SRL10] left, and
from NEUTRAL to [SFR10] or [SRR10] right. [SF---]
[SR---] is displayed when set for NEUTRAL [Figure 60-
170-1].

765 of 1052 60-170-1 T870 Service Manual

STEERING DRIFT COMPENSATION (OPERATOR Press the right scroll button on the left panel or the right
MODE) (CONT’D) button on the left control to adjust the machine back
toward center. The display will decrease down to
Operation (Cont’d) NEUTRAL displayed as [SF---] (Item 5). Another press of
the upper right button will cause [SFR01] (Item 6) to
Figure 60-170-2 appear in the data display (Item 1) [Figure 60-170-2].
The number will increase by one each time you press the
button up to a maximum of [SFR10]. The higher the
number, the greater the amount of steering drift
compensation to the right.

Forward steering drift compensation setting can be

2 adjusted with the steering controls in NEUTRAL or during
forward travel. Reverse steering drift compensation
3 setting can be adjusted during reverse travel. The letter
[R] will appear in place of the letter [F] in the data display
1 when setting reverse steering drift compensation.
NA3267 (EXAMPLES: [SRL01], [SRR01], and [SR---].

Exiting The Steering Drift Compensation Menu:

4 5 6
Press the Information button (Item 3) [Figure 60-170-2]
NA3227 / NA3229 / NA3231
to exit from the steering drift compensation adjustment
Left Right menu.

OR

If no buttons are pressed for 10 seconds, the display

screen will change to the hourmeter.
7

P107005D P107006D

Press the Information button (Item 3) to cycle the data

display until the steering drift compensation menu is
displayed. The current steering drift compensation setting
will appear in the data display (Item 1) [Figure 60-170-2].

Press the left or right scroll button (Item 2) [Figure 60-

170-2] on the left panel to adjust the setting. Adjustments
to steering drift compensation are effective immediately
and saved automatically.

OR

Press the left or right button (Item 7) [Figure 60-170-2]

on the left control to adjust the setting. Adjustments to the
steering drift compensation are effective immediately and
saved automatically.

Press the left scroll button on the left panel or the left
button on the left control to adjust the machine left.
[SFL01] (Item 4) through a maximum of [SFL10] will
appear in the data display (Item 1) [Figure 60-170-2].
The number will increase by one each time you press the
button. The higher the number, the greater the amount of
steering drift compensation to the left.

766 of 1052 60-170-2 T870 Service Manual

STEERING DRIFT COMPENSATION (SERVICE MODE) Operation

Description NOTE: Service Analyzer Software Version 81.3 or

higher is required for service mode.
The service mode allows a service technician to fine tune
straight travel, separate from the settings an operator Connect the Remote Start Tool (Service Tool). (See
may chose for a specific application. Saving an Remote Start Tool (Service Tool) - 7022042 on Page 10-
adjustment in service mode resets the operator mode to 61-2.)
NEUTRAL [ST--] or “0” on the scale.
Figure 60-171-2
Figure 60-171-1

Steering Drift Compensation

1

P115854

The Remote Start Tool (Item 1) [Figure 60-171-2]

enables service mode. Attach the tool to the loader
outside upright and route/tie the harness to avoid any
NA3232D
pinch points during machine operation.

Steering drift compensation contains a total of 21 NOTE: The remote start remains OFF during the
settings. Steering drift compensation can be set to any procedure but must be connected to enable
point from NEUTRAL to [STL10] left, and from service mode.
NEUTRAL to [STR10] right. [ST---] is displayed when set
for NEUTRAL [Figure 60-171-1].

WARNING
AVOID INJURY OR DEATH
• Always keep bystanders away from the work area
and travel path.
• The operator must always look in the direction of
travel.
W-2813-1209

Use a location with level ground and without bystanders

and drive the loader to determine the settings.

Operate the loader and warm the hydraulic oil before

making adjustments.

NOTE: Service mode adjustment will set operator

settings to NEUTRAL.

767 of 1052 60-171-1 T870 Service Manual

STEERING DRIFT COMPENSATION (SERVICE MODE) Figure 60-171-3
(CONT’D)

Operation (Cont’d)

Perform PRE-STARTING PROCEDURE and STARTING

THE ENGINE procedures:

1. Close door.

2. Fasten seat belt.

3. Lower seat bar. 1

NA3267

4. Put controls in NEUTRAL position.

2 3 4
5. Start the engine.
NA9046/NA9047/NA9048
6. Press the PRESS TO OPERATE LOADER button.
Left Right
7. Current drive response setting is displayed briefly in
the data display. Wait for machine to cycle to machine
hours.

NOTE: (SJC) Raising the seat bar or changing control

mode (ISO / H) will cause the machine to 5 6
disengage from steering drift compensation.
The last displayed setting will remain in effect P107005D P107006D
until the machine is turned OFF.

8. Press and hold the PRESS TO OPERATE LOADER Press the buttons on the left joystick (Item 5 and 6)
button for three seconds to enter drive response [Figure 60-171-3] to adjust. The number will change by
menu. one each time the button is pressed. Use the left button
to increase machine left or the right button to increase
9. Press the PRESS TO OPERATE LOADER button to machine right.
enter steering drift compensation adjustment.
Forward adjustment is performed with left joystick in
10. Current setting will appear. NEUTRAL or during forward travel. Reverse adjustment
is performed during reverse travel. Adjustments are
effective immediately.

NOTE: Using a high throttle setting will make the

machine response to adjustment more
obvious.

To save a desired setting, press and hold the PRESS TO

OPERATE LOADER button for three seconds. [SET] will
appear in the left panel (Item 1) [Figure 60-171-3] and
the machine will exit from the adjustment menu.

768 of 1052 60-171-2 T870 Service Manual

CONTROL PANEL SETUP Vitals

Right Panel Setup (Deluxe Instrumentation Panel)

Icon Identification Press a scroll button (Item

1) repeatedly until the
Figure 60-180-1 Vitals screen icon (Inset)
is highlighted.
1 1

Displays select system

operating levels.

You can monitor real-time displays of:

• Engine Speed
NA3189 • Engine Oil Pressure
• Engine Coolant Temperature
• Fuel Consumption
ICON DESCRIPTION • System Voltage
• Hydraulic Charge Pressure
DATE / TIME • Hydraulic Fluid Temperature
• Engine Oil Temperature
USER / HOURMETER
The Deluxe Instrumentation Panel is easy to use.
CURRENT JOB HOURS Continue to set your own preferences for operating /
monitoring your Bobcat loader.
ACTIVE WARNINGS screen icon

VITALS screen icon

SERVICE screen icon

MAIN screen icon

ATTACHMENTS screen icon

SECURITY screen icon

DISPLAY screen icon

HOME icon (Return to MAIN screen)

LEFT SCROLL button


RIGHT SCROLL button

ENTER button

769 of 1052 60-180-1 T870 Service Manual

CONTROL PANEL SETUP (CONT’D)

Right Panel Setup (Deluxe Instrumentation Panel) (Cont’d)

Date And Time English / Metric Display

Press a scroll button (Item

Press a scroll button (Item
1) repeatedly until the
1) repeatedly until the
Display screen icon (Inset)
Display screen icon (Inset)
is highlighted.
is highlighted.
1 1
1 1

Select [1. CLOCKS]. Select [4. DISPLAY

SETTINGS].

Select [1. TIME]. Press [1] to cycle between

ENGLISH and METRIC.

Use the keypad to enter

time. Auto Idle Time Delay

Select AM / PM / 24hr.

Press [ENTER] to Press a scroll button (Item
continue. 1) repeatedly until the
Security screen icon
(Inset) is highlighted.
1 1
Select [2. DATE].

Select [3. ENGINE

SETTINGS].

Use the keypad to enter

date.
 Use the keypad to enter
Press [ENTER] to the desired delay time
continue. between 4 and 250
seconds.

Press [ENTER] to save
and continue. Press left
scroll button to exit without
saving.

770 of 1052 60-180-2 T870 Service Manual

CONTROL PANEL SETUP (CONT’D)

Right Panel Setup (Deluxe Instrumentation Panel) (Cont’d)

Job Clock Reset Machine Lockouts

Press a scroll button (Item Press a scroll button (Item

1) repeatedly until the 1) repeatedly until the
Security screen icon Security screen icon
(Inset) is highlighted. (Inset) is highlighted.
1 1 1 1

Select [1. PASSWORDS /

LOCKOUTS]. Select [1. PASSWORDS /
LOCKOUTS].

Enter owner password

and press [ENTER]. Enter owner password
and press [ENTER].

Select [1. USER

SETTINGS]. Select [3. HIGH FLOW].

Select [4. TWO-SPEED].

Select user. HIGH FLOW

Press user number to

cycle between LOCKED
and UNLOCKED.

Select [3. RESET JOB

STATISTICS]. TWO-SPEED

Press user number to

cycle between LOCKED
and UNLOCKED.
Press [9] to reset job
statistics.

Press left scroll button or NOTE: High Flow and Two-Speed lockouts for the
[0] to exit without saving. owner are active even if the Password
Lockout feature is unlocked.

771 of 1052 60-180-3 T870 Service Manual

772 of 1052 60-180-4 T870 Service Manual
PASSWORD SETUP (DELUXE INSTRUMENTATION Changing The Owner Password
PANEL)

Password Setup is available on machines with a Deluxe

Instrumentation Panel. Press a scroll button (Item
1) repeatedly until the
Password Description Security screen icon
(Inset) is highlighted.
All new machines with a Deluxe Instrumentation Panel
1 1
arrive at Bobcat dealerships with the keypad in locked
mode. Locked mode means that a password must be Select [1. PASSWORDS /
used to start the engine. LOCKOUTS].

For security purposes, your dealer may change the

password and set the keypad in the locked mode. Your
dealer will provide you with the password.

Master Password:
Enter owner password
A permanent, randomly selected password set at the and press [ENTER].
factory that 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.

Owner Password:
Select [1. USER
Allows for full use of the loader and to set up the SETTINGS].
Deluxe Instrumentation Panel. There is only one
owner password. The owner password must be used
to change the owner or user passwords. Owner
should change the password as soon as possible for
security of the loader.

User Password: Select [1. OWNER].

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
Changing The User Passwords on Page 60-190-2.)
Select [2. CHANGE
PASSWORD].

Enter new owner

password and press
[ENTER].

You will be prompted to
reenter the new owner
password.

773 of 1052 60-190-1 T870 Service Manual

PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) (CONT’D)

Changing The User Passwords Password Lockout Feature

This feature allows the owner to unlock the password

feature so that a password does not need to be used
Press a scroll button (Item every time the engine is started.
1) repeatedly until the
Security screen icon
(Inset) is highlighted.
1 1 Press a scroll button (Item
1) repeatedly until the
Select [1. PASSWORDS / Security screen icon
LOCKOUTS]. (Inset) is highlighted.
1 1

Select [1. PASSWORDS /

LOCKOUTS].

Enter owner password

and press [ENTER].

Enter owner password

and press [ENTER].

Select [1. USER

SETTINGS].

Select [2. MACHINE

LOCK].

Select user.

NOTE: The procedure above can be followed to reset

the machine lock so that the machine requires
Select [2. CHANGE a password to start the engine.
PASSWORD].

Enter new user password

and press [ENTER].

774 of 1052 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 Turn the key switch to the RUN position to turn on the
factory that cannot be changed. This password is loaders electrical 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. Must be used to

change the owner password.

Changing The Owner Password

Turn the key switch to the RUN position to turn on the

loaders electrical system.

Enter the five digit owner password using the number

keys (1 through 0) if locked.
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 2 seconds. Turn the key switch to the RUN position 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 owner password using the number The lock key red light will flash and the left panel display
keys (1 through 0). An asterisk will show in the left panel screen will show [CODE].
display 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 owner password again.
You must now enter the password every time to start the
The lock key red light will become solid. loader.

775 of 1052 60-191-1 T870 Service Manual

776 of 1052 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

2
1

NA3086 NA3198

During machine operation, a 2 beep alarm will sound The Deluxe Instrumentation Panel (if equipped) will
when there are less than 10 hours until the next planned display a bar (Item 1) [Figure 60-200-3] showing the time
maintenance. remaining until next service. This bar will turn red when
service is past due. NEXT MAINTENANCE DUE will
The remaining hours before maintenance is required change to MAINTENANCE PAST DUE and display the
(Item 1) will appear in the data display for 5 seconds number of hours past due.
while the service icon (Item 3) and the hourmeter icon
(Item 2) [Figure 60-200-1] flash. Keys [4] and [9] can be used to adjust the service
interval when the owner is logged in [Figure 60-200-3].
NOTE: The display will show negative numbers after
counting down to zero.

The display will revert to the previous display and will

appear for 5 seconds every time the machine is started
until the maintenance clock is reset.

Figure 60-200-2

NA3195

The Deluxe Instrumentation Panel (if equipped) will

display a message (Item 1) [Figure 60-200-2] alerting
the operator to service the machine.

777 of 1052 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.

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.

778 of 1052 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]
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.

779 of 1052 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
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.

780 of 1052 60-200-4 T870 Service Manual

MAINTENANCE CLOCK (CONT’D)

Reset

Figure 60-200-16

NA3273

Press the Information button (Item 2) [Figure 60-200-16]

until the display screen shows the maintenance clock.

Press and hold the Information button (Item 2) for 7

seconds until [RESET] (Item 1) [Figure 60-200-16]
appears in the display screen.

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.

781 of 1052 60-200-5 T870 Service Manual

782 of 1052 60-200-6 T870 Service Manual
BACK-UP ALARM SYSTEM Inspecting

This machine may be equipped with a back-up alarm. Figure 60-210-2

Description

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.

Figure 60-210-1

1
P-90644C

Inspect for damaged or missing back-up alarm decal

(Item 1) [Figure 60-210-2]. Replace if required.

Sit in the seat and fasten the seat belt. Engage the
1 parking brake. Pull the seat bar all the way down. Start
the engine. Press the PRESS TO OPERATE LOADER
button. Disengage the parking brake.

Move both steering handles or joystick(s) into the reverse

position. The back-up alarm must sound when both
P121094
tracks are moving in reverse.

The Back-up Alarm (Item 1) [Figure 60-210-1] is located The back-up alarm is located on the inside of the rear
on the inside of the rear door. door.

A back-up alarm is not a substitute for looking to the Figure 60-210-3

rear when operating the loader in reverse, or for
keeping bystanders away from the work area.
Operators must always look in the direction of travel,
including reverse, and must also keep bystanders away
from the work area, even though the loader is equipped
with a back-up alarm.
1
Operators must be trained to always look in the direction
of travel, including when operating the loader in
reverse and to keep bystanders away from the work
area. Other workers should be trained to always keep
away from the operator’s work area and travel path.

2
P121187A

Inspect the back-up alarm electrical connections (Item 1)

and wire harness (Item 2) [Figure 60-210-3] for tightness
and damage. Repair or replace any damaged
components.

783 of 1052 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. correct function after adjustments, repairs or
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

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.

784 of 1052 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 60-210-4

P115871

Disconnect the alarm connectors (Item 1) [Figure 60-

210-4] from the alarm.

Remove the two nuts (Item 2) [Figure 60-210-4].

Remove the alarm and bracket from the loader.

785 of 1052 60-210-3 T870 Service Manual

786 of 1052 60-210-4 T870 Service Manual
FRONT HORN

Removal And Installation

Remove left side lower panel. (See Removal And

Installation on Page 50-160-1.)

Figure 60-220-1

P115951

Disconnect the wire harness (Item 1) [Figure 60-220-1]

from the front horn.

Figure 60-220-2

P115855

Remove the bolt and nut (Item 2) [Figure 60-220-1] and

[Figure 60-220-2].

Remove the front horn (Item 3) [Figure 60-220-2] from

the loader.

787 of 1052 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.
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)

788 of 1052 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.
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.

789 of 1052 60-220-3 T870 Service Manual

790 of 1052 60-220-4 T870 Service Manual
ENGINE COMPARTMENT TEMPERATURE SENSOR Figure 60-230-3

Removal And Installation

Remove the rear grille and side panels. (See Removing

on Page 50-60-1.)

WARNING 1

HOT SURFACES CAN CAUSE SERIOUS INJURY 1

• Do not touch.
• Allow to cool before servicing. P121609
W-2533-1012

Figure 60-230-1 Rotate the SCR clamps (Item 1) [Figure 60-230-3] to

remove. Discard the clamps.

NOTE: Do not reuse SCR clamps.

1
Installation: Tighten the nuts to 8 - 10 N•m (71 - 89 in-lb)
torque.
2
1 1 Figure 60-230-4

2
1

P121249

Remove the four bolts (Item 1) and the engine cover

(Item 2) [Figure 60-230-1].

Figure 60-230-2

1 P115863B

1
Remove the V-Band clamp (Item 1) and the gasket (Item
1
2) [Figure 60-230-4]. Discard the V-Band clamp and
gasket.

NOTE: Do not reuse the V-Band clamp or gasket.

Installation: Tighten the nut to 8 - 10 N•m (71 - 89 in-lb)

torque.

P121610

Remove the SCR clamp bolts (Item 1) [Figure 60-230-2].

791 of 1052 60-230-1 T870 Service Manual

ENGINE COMPARTMENT TEMPERATURE SENSOR
(CONT’D)

Removal And Installation (Cont’d)

Reposition the SCR to allow access to the temperature

sensor.

Figure 60-230-5

1 2

P115928

Remove the electrical connector (Item 1) [Figure 60-230-

5] from the sensor.

Remove the nut and sensor (Item 2) [Figure 60-230-5].

Installation: Tighten the nut to 15 N•m (11 ft-lb) torque.

792 of 1052 60-230-2 T870 Service Manual

 ENGINE SERVICE

ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-4
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-13
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-15
Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-26
Compression - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-28
Injector Signal - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-30
Injector Signal - Testing (In-Line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-32

ENGINE SPEED CONTROL (HAND) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

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

ENGINE SPEED CONTROL (FOOT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-2
Foot Throttle Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-4

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Diesel Exhaust Fluid (DEF) / AdBlue® Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-2
DeSOX Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-3
SCR System Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-5
Diesel Exhaust Fluid (DEF) / AdBlue® Unsatisfactory Quality . . . . . . . . . . . . . . . . . 70-30-6
SCR System Component Tampering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-6
EGR Impeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-7
Diesel Exhaust Fluid (DEF) / AdBlue® Dosing Interruption . . . . . . . . . . . . . . . . . . . 70-30-7
SCR Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-8
Dosing Module Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-10
Dosing Control Unit (DCU) Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-30-11
Supply Module Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-13
Supply Module Filter Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-14
Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal And Installation 
(Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-16
Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal And Installation 
(Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-19
Diesel Exhaust Fluid (DEF) / AdBlue® Sensor Removal And Installation 
(Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-21
Diesel Exhaust Fluid (DEF) / AdBlue® Coolant Valve Removal 
And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-23

DIESEL OXIDATION CATALYST (DOC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

793 of 1052 70-01 T870 Service Manual

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Radiator / Oil Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Hydraulic Fan Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4
Hydraulic Reversing Fan Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4
Lower Fan Duct Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4
Hydraulic Fan Motor Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-60-5
Hydraulic Fan Motor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-7
Hydraulic Fan Motor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-8
Blower Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-16
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-17
Thermostat Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-17
Thermostat - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-18

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-3
Oil Pump Relief Valve Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-4
Oil Suction Pipe Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-4
Oil Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-5
Oil Filter Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-5
Oil Cooler Bypass Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-6

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
High Pressure Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-2
High Pressure Pump Drive Gear Removal And Installation . . . . . . . . . . . . . . . . . . . 70-80-4
Fuel Temperature Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-4
Fuel Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-4
Fuel Cooler Bypass Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-80-5
Fuel Recirculation Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-6
Fuel Rail Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Injector Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-10
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-12

794 of 1052 70-02 T870 Service Manual

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Intake Air Heater Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Intake Air Heater Tube Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-2
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-3
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-5
Cylinder Head Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-8
Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-9
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-10
Valve Step Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-11
Valve Stem Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-11
Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-12
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-12
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-13
Rocker Arm Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-14
Rocker Arm Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-15
Push Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-15

CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

Piston And Connecting Rod Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Piston And Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-2
Timing Wheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-4
Crankshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Cylinder Block Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-8
Crankshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-10
Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-10
Engine Component Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-11

CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-2

GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Gear End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Gear Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-2
Idle Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-3
Idle Gear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-3

TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-3

FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-1

Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-1
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-2

795 of 1052 70-03 T870 Service Manual

EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 70-150-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-150-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-150-2

DIESEL EXHAUST FLUID (DEF) / ADBLUE® SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 70-160-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-160-1
Filling The DEF / AdBlue® Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-160-1

796 of 1052 70-04 T870 Service Manual

ENGINE INFORMATION

Description

Figure 70-10-1

P121107

The loader is equipped with a Bobcat direct injected

D34P turbo charged and intercooled diesel engine with a
displacement of 3,4 L (208 in3). The loader is equipped
with one of two engine ratings. S/N AJ9C11001 & Above
and S/N B3BY11001 & Above is equipped with an engine
rated at an SAE J gross 69,6 kW (93.3 hp) @ 2400 rpm.
S/N B47711001 & Above is equipped with an engine
rated at an SAE J gross 75,6 kW (101.4 hp) @ 2400 rpm.
The engine has a closed breather 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 electronic timer with cold
start advance function for assisting in cold starts.

To meet emission regulations it is also equipped with a

Selective Catalytic Reduction (SCR) system and 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 high pressure pump. The model
number is located on the valve cover. Use these numbers
to obtain the correct service parts.

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, the hydraulic / hydrostatic
fluid temperature sensor, fuel temperature and the HVAC
system.

797 of 1052 70-10-1 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Specifications

Valve Springs
Free Length (Intake and Exhaust) 55,23 mm (2.17 in)
Tilt Allowable Limit (Intake and Exhaust) Below 1,8 mm (0.071 in)

Valve
Valve Clearance (Intake) 0,4 mm (0.016 in)
Valve Clearance (Exhaust) 0,45 mm (0.018 in)
Valve Stem OD (Intake) 6,97 ± 0,007 mm (0.274 ± 0.0003 in)
Valve Stem OD (Exhaust) 6,97 ± 0,007 mm (0.274 ± 0.0003 in)
Valve Face Width (Intake) 2,14 mm (0.084 in)
Valve Face Width (Exhaust) 1,63 mm (0.064 in)
Valve Face Angle 44,5° - 45.0°
Valve Guide Bore 7.0 - 7.015 mm (0.2756 - 0.2762 in)
Valve Guide Length 43,4 - 43,6 mm (1.7087 - 1.7165 in)

Valve Timing
Intake Valve (Open) 16 degrees B.T.D.C.
(Close) 54 degrees A.B.D.C.
Exhaust Valve (Open) 38 degrees B.B.D.C.
(Close) 24 degrees A.T.D.C.

Rocker Arms
O.D. of Rocker Arm Shaft 16,15 mm (0.6358 in)
I.D. of Rocker Arm Bushings 16,03 mm (0.6311 in)

Camshaft
Journal O.D. 44,950 - 44,966 mm (1.7697 - 1.7703 in)
Bearing I.D. 45,0 - 45,025 mm (1.7717 - 1.7726 in)
Oil Clearance 0,065 - 0,106 mm (0.0026 - 0.0042 in)
Camshaft End Play 0,1 - 0,2 mm (0.0039 - 0.0079 in)
Cam Lobe Height (Intake) 39,78 mm (1.566 in)
Cam Lobe Height (Exhaust) 38,716 mm (1.524 in)
Side Clearance Allowable Limit 0,1 - 0,2 mm (0.0039 - 0.0079 in)

Cylinder Bore
Cylinder Bore I.D. 97,990 - 98,010 mm (3.8579 - 3.8587 in)

Piston Rings
Ring Gap (Top Ring) 0,25 - 0,40 mm (0.0098 - 0.0157 in)
Ring Gap (2nd Ring) 0,55 - 0,70 mm (0.0217 - 0.0276 in)
Ring Gap (Oil Ring) 0,20 - 0,40 mm (0.0079 - 0.0157 in)
Side Clearance of Ring Groove:
Top Ring 0,083 - 0,137 mm (0.0033 - 0.0054 in)
Second Ring 0,070 - 0,110 mm (0.0276 - 0.0043 in)
Oil Ring 0,030 - 0,070 mm (0.0012 - 0.0028 in)

Pistons
Piston Pin Bore 31,008 - 31,014 mm (1.2208 - 1.2210 in)

798 of 1052 70-10-2 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Specifications (Cont’d)

Connecting Rod
Piston Pin O.D. 35,995 - 36,000 mm (1,4171- 1.4173 in)
Small End Bushing I.D. 36,025 - 36,038 mm (1.4183 - 1.4188 in)
Oil Clearance Between Piston Pin and Small End Bushing 0,025 - 0,043 mm (0.0010 - 0.0017 in)

Oil Pump
Oil Pressure Rated rpm 294 - 539 kPa (2,94 - 5,39 bar) (43 - 78 psi)
Idle Speed Allowable Limit 147 - 294 kPa (1,47 - 2,94 bar) (21 - 43 psi)

Crankshaft
Connecting Rod Large End Bore 66,000 - 66,015 mm (2.5984 - 2.5990 in)
Connecting Rod Oil Clearance (Large End Bore) 0,026 - 0,064 mm (0.0001 - 0.0025 in)
Connecting Rod End Play 0,15 - 0,30 mm (0.0059 - 0.0118 in)
Crankshaft Journal O.D. 74,955 - 74,970 mm (2.9510 - 2.9516in)
Oil Clearance Between Journal and Bearing 0,029 - 0,059 mm (0.0011 - 0.0023 in)
Crankshaft End Play 0,10 - 0,31 mm (0.0039 - 0.0122 in)
I.D. of Cylinder Block Main Bearing Bore
Class A 79,000 - 79,007 mm (3.1102 - 3.1105 in)
Class B 79,007 - 79,014 mm (3.1105 - 3.1108 in)
Class C 79,014 - 79,021 mm (3.1108 - 3.1111 in)
OD of Crankshaft Main Journal
Class A 74,955 - 74,960 mm (2.9510 - 2.9512 in)
Class B 74,960 - 74,965 mm (2.9512 - 2.9514 in)
Class C 74,965 - 74,970 mm (2.9514 - 2.9516 in)
Main Bearing Thickness
Blue 1,995 - 2,000 mm (0.0785 - 0.0787 in)
Yellow 2,000 - 2,005 mm (0.0787 - 0.0789 in)
Red 2,005 - 2,010 mm (0.0789 - 0.0791 in)

Timing Gear
Timing Gear Backlash:
High Pressure Pump Gear To Idle Gear 0,081 - 0,196 mm (0.0032 - 0.0077 in)
Idle Gear To Crankshaft Gear 0,087 - 0,202 mm (0.0034 - 0.0080 in)
Idle Gear To Camshaft Gear 0,087 - 0,213 mm (0.0034 - 0.0084 in)
Crankshaft Gear To Oil Pump Gear 0,066 - 0,247 mm (0.0026 - 0.0097 in)

Thermostat
Valve Opening Temperature 82°C (180°F)
Valve Fully Open 97°C (207°F)

799 of 1052 70-10-3 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Sensor Location

Vehicle Side

Figure 70-10-2

2 6

4 5 3

P121122

1. Mass Air Flow Sensor (MAF) (Item 1) [Figure 70-10-

2]

2. Coolant Temperature Sensor (Item 2) [Figure 70-10-

2]

3. Camshaft Position Sensor (Item 3) [Figure 70-10-2]

4. Crankshaft Position Sensor (Item 4) [Figure 70-10-2]

5. EGR Valve Actuator (Item 5) [Figure 70-10-2]

6. Turbo Exhaust Gas Temperature Sensor (Item 6)

[Figure 70-10-2]

800 of 1052 70-10-4 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Sensor Location (Cont’d)

Tailgate (Service) Side

Figure 70-10-3

2 2

5
3
P121123

1. Intake Manifold Pressure Sensor (MAP) (Item 1) Figure 70-10-4

[Figure 70-10-3]

2. Knock Sensor (Item 2) [Figure 70-10-3]

3. Oil Pressure / Temperature Sensor (Item 3) [Figure

70-10-3]

4. Intake Manifold Temperature Sensor (Item 4) [Figure 1

70-10-3]

5. Fuel Temperature Sensor (Item 5) [Figure 70-10-3]

P121135

Common Rail Pressure Sensor (Item 1) [Figure 70-10-4]

801 of 1052 70-10-5 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-7

Sensor Location (Cont’d)

Figure 70-10-5

1
1

P121136
2

Camshaft Position Sensor (Item 1) [Figure 70-10-7].

P121138
Figure 70-10-8

Mass Air Flow Sensor (MAF) (Item 1) [Figure 70-10-5].

Engine Compartment Temperature Sensor (Item 2)

[Figure 70-10-5].

Figure 70-10-6

1 P121131

Crankshaft Position Sensor (Item 1) [Figure 70-10-8].

P121128

Coolant Temperature Sensor (Item 1) [Figure 70-10-6].

802 of 1052 70-10-6 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-11

Sensor Location (Cont’d)

Figure 70-10-9

P121134

Intake Manifold Pressure Sensor (MAP) [Figure 70-10-

P121137 11].

Figure 70-10-12
EGR Valve Actuator (Item 1) [Figure 70-10-9].

Figure 70-10-10

P121127

P121129 Knock Sensor (Left Side) (Item 1) [Figure 70-10-12].

Turbo Exhaust Gas Temperature Sensor (Item 1) [Figure

70-10-10].

803 of 1052 70-10-7 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-15

Sensor Location (Cont’d)

Figure 70-10-13
1

P121133

Intake Manifold Temperature Sensor (Item 1) [Figure 70-

P121132 10-15].

Figure 70-10-16
Knock Sensor (Right Side) (Item 1) [Figure 70-10-13].

Figure 70-10-14

P121125

P121126 Fuel Temperature Sensor (Item 1) [Figure 70-10-16].

Inlet Metering Valve (Item 2) [Figure 70-10-16].

Oil Pressure / Temperature Sensor (Item 1) [Figure 70-
10-14].

804 of 1052 70-10-8 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-19

Sensor Location (Cont’d)

Figure 70-10-17

1
2 2

P115875

Diesel Oxidation Catalyst (DOC) Temperature Sensor

P115946 (Item 1) [Figure 70-10-19] (if equipped).

Diesel Oxidation Catalyst (DOC) Upstream NOx Sensor

Engine Control Unit (ECU) (Item 1) [Figure 70-10-17]. (Item 2) [Figure 70-10-19].

Atmospheric Pressure Sensor (Item 2) [Figure 70-10- Figure 70-10-20

17].

Figure 70-10-18

1 P115867

P115883 Selective Catalytic Reduction (SCR) Temperature Sensor

(Outlet Side) (Item 1) [Figure 70-10-20]. (If equipped.)

Water in Fuel Sensor (Item 1) [Figure 70-10-18]. Selective Catalytic Reduction (SCR) Downstream NOx
Sensor (Item 2) [Figure 70-10-20].

805 of 1052 70-10-9 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Sensor Location (Cont’d)

Figure 70-10-21

P120660

Selective Catalytic Reduction (SCR) temperature sensor

(inlet side) (Item 1) [Figure 70-10-21].

806 of 1052 70-10-10 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Torque Values

Thread Size
Strength Classification
(Dia. x Pitch)
8.8 10.9 12.9
M6 x 1,0 9,8 N•m 12,3 N•m 14,7 N•m
(7.2 ft-lb) (9 ft-lb) (10.8 ft-lb)
M8 x 1,25 21,6 N•m 30,4 N•m 37,3 N•m
(15.9 ft-lb) (22.4 ft-lb) (27.5 ft-lb)
M8 x 1,0 23,5 N•m 32,8 N•m 40,2 N•m
(17.4 ft-lb) (24.2 ft-lb) (29.7 ft-lb)
M10 x 1.5 43,1 N•m 60,8 N•m 72,6 N•m
(31.8 ft-lb) (44.8 ft-lb) (53.5 ft-lb)
M10 x 1,0 49 N•m 68,6 N•m 82,4 N•m
(36.2 ft-lb) (50.6 ft-lb) (60.8 ft-lb)
M12 x 1,75 73,5 N•m 103 N•m 122,6 N•m
(54.2 ft-lb) (76 ft-lb) (90.4 ft-lb)
M12 x 1,5 78,5 N•m 109,8 N•m 131,5 N•m
(57.9 ft-lb) (81 ft-lb) (97 ft-lb)
M14 x 1,5 127,5 N•m 181,4 N•m 215,7 N•m
(94 ft-lb) (134 ft-lb) (159 ft-lb)

807 of 1052 70-10-11 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Torque Values (Cont’d)

Thread Size Strength

Component Tightening Torque
(Diameter X Pitch) Class
54 N•m (40 ft-lb) initial torque
Main Bearing Cap Bolt M12x1.5x133 12.9 Plus 90° second torque
Plus 90° third torque
44 N•m (33 ft-lb) initial torque
Cylinder Head Bolt M12x1.25x29 9.8 Plus 90° second torque
Plus 90° third torque
29,4 N•m (21.7 ft-lb) initial torque
Connecting Rod Bolt M9x1.0x66 10.9
Plus 90° second torque
Crankshaft Pulley Bolt M14x1.5 10.9 245 - 265 N•m (181 - 195 ft-lb)
Cylinder Head Cover Bolt M6x1.0 8.8 7,8 N•m (5.8 ft-lb)
Injector Bracket Bolt M8x1.25 12.9 39 - 46 N•m (29 - 34 ft-lb)
Thermostat Bolt M8x1.25 8.8 22 N•m (16 ft-lb)
Turbocharger Hollow Screw M10x1.0 19,6 N•m (14.5 ft-lb)
Turbocharger Nut M8x1.25 22 N•m (16 ft-lb)
Water Pump Nut and Bolt M8x1.25 22 N•m (16 ft-lb)
Rocker Arm Adjust Nut M8x1.0 14,7 N•m (10.8 ft-lb)
High Pressure Pump Drive Gear Nut M14x1.5 58,8 - 68,6 N•m (43.4 - 50.6 ft-lb)
High Pressure Pump Nut M8x1.25 22 N•m (16 ft-lb)
Turbocharger Oil Delivery Pipe Nut Nut 19,6 N•m (14.5 ft-lb)
High Pressure Pipe Nut - High Pressure
Nut 27,5 - 31,4 N•m (20.3 - 23.1 ft-lb)
Pump
High Pressure Pipe Nut - Common Rail Nut 27,5 - 31,4 N•m (20.3 - 23.1 ft-lb)
High Pressure Pipe Nut - Injector Nut 27,5 - 31,4 N•m (20.3 - 23.1 ft-lb)

808 of 1052 70-10-12 T870 Service Manual

ENGINE INFORMATION (CONT’D)

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, 53
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14,15, 18, 26, 27, 28
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15,16, 17, 18, 19, 24, 26, 27, 28,53
No power for engine. 8, 9, 10, 11, 12, 13, 15,16, 17, 19, 20, 21, 22, 26, 27, 28
Engine is mis-firing. 8, 9, 11, 12, 13, 15, 16, 20, 21, 23, 24, 25, 27
Too much fuel consumption. 10, 12, 13, 15,16, 18, 19, 20, 22, 23, 24, 26, 27, 28
Black exhaust. 10, 12, 13, 15,16, 18, 19, 20, 22, 23, 24, 26, 27, 28
Blue / white exhaust. 4, 10, 15, 16, 20, 22, 26, 28, 29, 49
Low oil pressure. 4, 30, 31, 32, 33, 34, 36, 37, 38, 51
Engine knocking. 13, 15, 18, 21, 23, 24, 26, 28, 30, 39, 40, 52
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 16, 17, 21, 23, 24, 25, 28, 39, 52
Vibration. 12, 13, 16, 20, 21, 24, 25, 28, 39, 41, 42
High oil pressure warning. 4, 32, 35
Overheating. 10, 12, 13, 15, 19, 20, 39, 43, 44, 45, 46, 47, 50
Too much crankcase pressure. 21, 26, 28, 29, 39, 48
Poor compression. 10, 15, 20, 23, 24, 26, 27, 28, 29, 40, 52
Start and stop. 9, 10, 11

809 of 1052 70-10-13 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Troubleshooting (Cont’d)

KEY TO CORRECT THE CAUSE

1. Alternator belt is loose or damaged. 28. Broken or worn piston rings.
2. Bad electrical connections. 29. Worn valve stems or guides.
3. Faulty starter motor. 30. Worn or damaged bearings.
4. Incorrect grade of oil. 31. Not enough oil in the crankcase.
5. Low cranking speed. 32. Switch / sensor is defective.
6. Fuel tank empty. 33. Oil pump worn.
7. Faulty stop control operation. 34. Relief valve is sticking open.
8. Plugged fuel line. 35. Relief valve is sticking closed.
9. Plugged fuel filter. 36. Broken relief valve spring.
10. Restriction in the air cleaner. 37. Faulty suction pipe.
11. Air in the fuel system. 38. Plugged oil filter.
12. Faulty fuel injection pump. 39. Piston seizure.
13. Faulty fuel injectors. 40. Incorrect piston height.
14. Broken injection pump drive. 41. Faulty engine mounting.
15. Incorrect valve timing. 42. Incorrect flywheel alignment.
16. Poor compression. 43. Faulty thermostat.
17. Plugged fuel tank vent. 44. Restriction in water jacket.
18. Incorrect grade of fuel. 45. Loose alternator belt.
19. Exhaust pipe restriction. 46. Plugged radiator.
20. Cylinder head gasket leaking. 47. Faulty water pump.
21. Overheating. 48. Plugged breather pipe.
22. Cold running. 49. Damaged valve stem deflectors.
23. Incorrect tappet adjustment. 50. Coolant level to low.
24. Sticking valves. 51. Plugged oil pump pipe strainer.
25. Incorrect fuel lines. 52. Broken valve spring.
26. Worn cylinder bores. 53. Damaged Battery
27. Worn valve and seats.

810 of 1052 70-10-14 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-24

Engine Removal And Installation

Figure 70-10-22

P100332

Use the engine removal tool (MEL1653-1) [Figure 70-10-

22] and the attachment (MEL1653-11) [Figure 70-10-23]
and (MEL1653-8) [Figure 70-10-24] to aid in the removal
and installation of the engine.

P-76872

Figure 70-10-23

P115885

811 of 1052 70-10-15 T870 Service Manual

ENGINE INFORMATION (CONT’D) Remove the AC compressor (if equipped). (See Removal
And Installation on Page 80-50-1.)
Engine Removal And Installation (Cont'd)
Figure 70-10-25

DANGER
2

P-90328

AVOID DEATH
• Disconnecting or loosening any hydraulic P115920

tubeline, hose, fitting, component or a part failure

can cause lift arms to drop. Remove the engine ground cable and chassis ground
• Keep out of this area when lift arms are raised cable (Item 1) [Figure 70-10-25].
unless supported by an approved lift arm
support. Replace if damaged. Remove the engine starter positive cable (Item 2)
D-1009-0409
[Figure 70-10-25] from the starter.

Figure 70-10-26

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
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 10-20-2.)

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

P115921

Drain the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-120-2.)
Remove the tie strap (Item 1) and disconnect the
Remove the battery from the loader. (See Removal And connector (Item 2) [Figure 70-10-26].
Installation on Page 60-20-1.)
Drain the engine coolant from the cooling system. (See
Removing And Replacing Coolant on Page 10-90-5.)
Remove the SCR. (See SCR Removal And Installation
on Page 70-30-8.)

Remove the DOC. (See Removal And Installation on

Page 70-40-1.)

Remove the fan duct panels. (See Removal And

Installation on Page 50-190-1.)

812 of 1052 70-10-16 T870 Service Manual

ENGINE INFORMATION (CONT’D) Installation: If equipped with a fuel recirculation valve,
use the procedure on page 70-80-12 to remove air from
Engine Removal And Installation (Cont'd) the fuel system.

Figure 70-10-27 Figure 70-10-29

1
3

3
2 2
1

P115922 P121903

Disconnect the two wires (Item 1), remove the wire mount Disconnect the harness (Item 1) [Figure 70-10-29] from
bolt (Item 2) and reposition the air heater wire (Item 3) the bottom of the filter.
[Figure 70-10-27].
Remove the two bolts (Item 2) and reposition the fuel
filter assembly (Item 3) [Figure 70-10-29].

WARNING Figure 70-10-30

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. 1
W-2103-0508

Figure 70-10-28

P121241

1 Remove the hose / clamp (Item 1) [Figure 70-10-30]

from the charge air cooler (left side).

P115923

Remove the fuel inlet line (Item 1) and the fuel return line
(Item 2) [Figure 70-10-28] from the high pressure pump.
Install caps and plugs.

813 of 1052 70-10-17 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-33

Engine Removal And Installation (Cont'd)

Figure 70-10-31

1
1

2
P120680

Remove the three coolant hoses (Item 1) [Figure 70-10-

P121242 33].

Figure 70-10-34
Remove the hose / clamp (Item 1) [Figure 70-10-31]
from the charge air cooler (right side).
2
Figure 70-10-32

2 P115926

Loosen and reposition the hose clamp (Item 1) [Figure

P115924 70-10-34].

Remove the tie strap (Item 2) [Figure 70-10-34].

Remove the radiator hose / clamp (Item 1) and (Item 2)
[Figure 70-10-32].

814 of 1052 70-10-18 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-37

Engine Removal And Installation (Cont'd)

Figure 70-10-35

4
1

1
2
3

3 P115928

2 Remove the wire from the mass air flow sensor (Item 1)
P115857A and the engine compartment temperature sensor (Item
2) [Figure 70-10-37].

Disconnect the wire harnesses (Item 1) [Figure 70-10- Remove the tie strap (Item 3) and the two bolts (Item 4)
35]. [Figure 70-10-37].

Remove the two bolts (Item 2) and reposition the NOx Remove the assembly from the machine.
brackets (Item 3) [Figure 70-10-35].
Figure 70-10-38
Figure 70-10-36

P115872
P115858A

Remove the engine connector (Item 1) from the ECU

Loosen the hose clamp (Item 1) [Figure 70-10-36] and (Item 2) [Figure 70-10-38]. (See Removal And
disconnect the hose from the air cleaner. Installation on Page 60-90-3.)

NOTE: The connectors / ECU must be thoroughly

cleaned. DO NOT USE PRESSURIZED
WATER. Use compressed air and small brush.

815 of 1052 70-10-19 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-41

Engine Removal And Installation (Cont'd)

1
Figure 70-10-39

P115820

Remove the two bolts (Item 1) [Figure 70-10-41].

P115929
Figure 70-10-42

Disconnect the wire harness connector (Item 1) [Figure

70-10-39].

Figure 70-10-40

1
2 1
1
P115828

Remove the fuel hose / clamp (Item 1) [Figure 70-10-42]

from the filler neck.
P115930

Cut the tie straps and (Item 1) and reposition the wire
harness (Item 2) [Figure 70-10-40].

816 of 1052 70-10-20 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-44

Engine Removal And Installation (Cont'd)

Figure 70-10-43
1
1 2

P115927

Remove the inlet hose (Item 1) [Figure 70-10-44] from

P115821 the fan.

Remove the outlet hose (Item 2) [Figure 70-10-44] from

Remove the clamp / hose (Item 1) [Figure 70-10-43] the fan.
from the tank.
Figure 70-10-45
NOTE: Plug the fuel tank opening.

IMPORTANT
2
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 1

P115932

Mark the location of the four hoses (Item 1) [Figure 70-

10-45] and disconnect.

Remove the case drain hose (Item 2) [Figure 70-10-45]

from the pump.

NOTE: The fittings on the hydrostatic pump must be

tightened to 128 - 138 N•m (94 - 102 ft-lb)
torque.

817 of 1052 70-10-21 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-48

Engine Removal And Installation (Cont'd)

Figure 70-10-46

1 1

2 P115935

Disconnect the hydrostatic pump connectors (Item 1)

P115933 [Figure 70-10-48].

Figure 70-10-49
Remove both suction hoses (Item 1) [Figure 70-10-46]
from the pump.

Remove the charge pump inlet hose (Item 2) [Figure 70-

10-46].
1
Figure 70-10-47

P115936

Remove the inlet hose (Item 1) [Figure 70-10-49] from

the bottom of the hydraulic control valve.
1

P115934

Remove the case drain hose (Item 1) [Figure 70-10-47]

from the drain manifold.

818 of 1052 70-10-22 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-52

Engine Removal And Installation (Cont'd)

Figure 70-10-50

P115940

Remove the engine mounting bolt (Item 1) [Figure 70-

P100806 10-52] from the left side of the engine.

Installation: Tighten the mounting bolt to 122 - 135 N•m

Disconnect the two Bob-Tach electrical solenoid coil (90 - 100 ft-lb) torque.
connectors (Item 1) [Figure 70-10-50] from the loader
electrical harness (if equipped). Figure 70-10-53

Figure 70-10-51

1
1

P115941

P115939
Remove the engine mounting bolt (Item 1) [Figure 70-
10-53] from the right side of the engine.
Remove rear engine mounting bolt (Item 1) [Figure 70-
10-51]. Installation: Tighten the mounting bolt to 122 - 135 N•m
(90 - 100 ft-lb) torque.
Installation: Tighten the mounting bolt to 122 - 135 N•m
(90 - 100 ft-lb) torque.

819 of 1052 70-10-23 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-56

Engine Removal And Installation (Cont'd)

Figure 70-10-54
2

1 3
1
3

P115942

2
Install the engine removal tool (Item 1) and the extension
P115944 (Item 2) into the engine removal bracket (Item 3) [Figure
70-10-56].

Remove the bolt (Item 1) and bolt / ground cable (Item 2) Figure 70-10-57
[Figure 70-10-54].

Remove the battery hold down plate (Item 3) [Figure 70-

10-54].
1
Figure 70-10-55

2
1

2
2 P115943

Connect a chain hoist (Item 1) to the engine removal tool

(Item 2) [Figure 70-10-57].

P115938

Install the engine removal bracket (Item 1) on the engine

using the SCR mounting hardware (Item 2) [Figure 70-
10-55].

820 of 1052 70-10-24 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Engine Removal And Installation (Cont'd)

Figure 70-10-58

1 1

P106863

Raise the engine and pull the engine out of the loader far
enough to remove the power Bob-Tach hoses (Item 1)
[Figure 70-10-58] (if equipped).

Remove the engine / hydrostatic pump assembly from

the loader.

821 of 1052 70-10-25 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-60

Engine Mount Replacement Washer

Engine
Figure 70-10-59 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 70-10-60].

Tighten the mounting bolts to 122 - 135 N•m (90 - 100 ft-
Use the following procedure to install new rear engine lb) torque.
mount:
Figure 70-10-61
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 70-10-59]: 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 70-10-61].
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)

822 of 1052 70-10-26 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Engine Mount Replacement (Cont’d)

Figure 70-10-62

Washer
Engine
Mounting
Bracket

Engine
Mount

Snubbing
Washer
Spacer
Loader
Frame P-85987

Install the new engine mount as shown in the cut away

side view [Figure 70-10-62].

Tighten the mounting bolts to 122 - 135 N•m (90 - 100 ft-
lb) torque.

823 of 1052 70-10-27 T870 Service Manual

ENGINE INFORMATION (CONT’D) NOTE: High pressure lines and return fuel lines are
single use lines. Replace with new.
Compression - Testing
Sealing washers must be replaced with new
NOTE: Specifications are subject to change without when installing the injectors. Save the old
notice. sealing washers to use with the compression
adapter.
Prior to performing an engine compression test with a
gauge, it is recommended to perform a compression test Figure 70-10-64
using Bobcat Engine Analyzer software to determine if a
potential compression issue exists.
1
Wash the machine and then thoroughly clean the
external portion of the fuel system components and the
surrounding area of the engine compartment with
compressed air. Perform engine service in a clean
environment.

After warming up the engine, stop the engine, wait five

minutes for fuel pressure bleed down then remove all the
injectors. (See Fuel Injector Removal And Installation on
2
Page 70-80-8.)

Figure 70-10-63 NA13030

Install the compression tester and test adapter (part

number 7299827) for diesel engines into the nozzle hole
(Item 1) [Figure 70-10-64].

Use one of the old sealing washers to seal the adapter.

Remove the fuel line at the fuel filter outlet so no fuel is

expelled.

Plug the fuel line and cap the fuel filter outlet to help
maintain fuel system cleanliness.

P127114 NOTE: Always use a fully charged battery for

performing this test.

When removing the injectors leave the fuel lines Monitor the engine crank speed to ensure that a
connected to the fuel rail. Reroute the lines to allow any minimum of 180 rpm is achieved or reading will not be
small amount of fuel that may be present during the test valid.
to be collected [Figure 70-10-63].
Connect the Bobcat Engine Analyzer Diagnostic Tool and
Leaving the fuel lines connected to the fuel rail will also run the Compression test in Bobcat Engine Analyzer.
help prevent debris from entering the fuel rail. This test will cause the engine to crank while the test is
running. Observe the maximum compression reading on
Store each of the injectors in a new clean plastic bag. the compression gauge during cranking, not the test
results shown on the computer screen.
NOTE: Number the plastic bags to ensure that
injectors are installed in the same cylinders Repeat this procedure multiple times per cylinder until an
from which they were removed. average reading is recorded.

Do not get the injectors out of order. If the

injectors get out of order, it is necessary to
perform injector coding. (See Injector Coding
on Page 70-80-10.)

824 of 1052 70-10-28 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Compression - Testing (Cont’d)

Use the table below to determine if the results are within

acceptable limits.

Compression Factory 2,9 - 3,5 MPa / 200 rpm

Pressure spec. (29 - 35 bar / 200 rpm) 
(420 - 508 psi / 200 rpm)
Allowable 2,5 MPa / 200rpm
Limit (25 bar / 200 rpm)
(290 psi / 200 rpm)
Variance Factory 300Kpa (3 bar) (44 psi)
Among Spec.
Cylinders Allowable 300Kpa (3 bar) (44 psi)
Limit

If the measurement is below the allowable limit, apply a

small amount of oil to the cylinder wall through the nozzle
hole and measure the compression again.

If the compression pressure increases after applying oil,

cylinder wall and/or piston ring damage may be possible.
A bore scope may be used to look for internal damage
prior to engine disassembly.

If the compression pressure is still less than the allowable

limit, check the top clearance, valves and cylinder head.

825 of 1052 70-10-29 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-66

Injector Signal - Testing

NOTE: Engine should be allowed to cool completely

1
before performing the following procedure.

The tool listed will be needed to the following procedure:

7299829 - Injector Signal Tester

MEL1563 or 7217666 - Remote Start Tool 2

WARNING
P115882

AVOID INJURY OR DEATH

Wear safety glasses to prevent eye injury when any
Remove the connector (Item 1) from the injector (Item 2)
of the following conditions exist:
[Figure 70-10-66].
• When fluids are under pressure.
• Flying debris or loose material is present.
Figure 70-10-67
• Engine is running.
• Tools are being used.
W-2019-0907

Open the rear door. 1 2

Remove the SCR. (See SCR Removal And Installation

on Page 70-30-8.)

NOTE: Ensure the battery is fully charged before

testing.

Figure 70-10-65

P127169

Install the signal tester (Item 1) to the connector (Item 2)

[Figure 70-10-67].

NOTE: Injector connector must be properly oriented

with tester connector or damage will occur.
1
Do not pull on wires or LED holder.

Connect the Remote Start Tool. (See REMOTE START

TOOL KIT - MEL1563 on Page 10-60-1.) or (See
P115882 REMOTE START TOOL (SERVICE TOOL) KIT -
7217666 on Page 10-61-1.)

Locate the fuel injectors (Item 1) [Figure 70-10-65].

826 of 1052 70-10-30 T870 Service Manual

ENGINE INFORMATION (CONT’D)

Injector Signal - Testing (Cont’d)

Figure 70-10-68

P-76439

Press the RUN button (Item 1) [Figure 70-10-68] on the

Remote Start Tool.

Figure 70-10-69

P127170

The signal tester light (Item 1) [Figure 70-10-69] should

flash once.

To repeat the test, press the STOP button (Item 2)

[Figure 70-10-68] and wait one minute.

If the signal tester light flashes, the electrical system is

working.

If the signal tester light is on continuously or not at all,

there is an electrical malfunction.

Repeat the above procedure for the remaining injectors.

827 of 1052 70-10-31 T870 Service Manual

ENGINE INFORMATION (CONT’D) Figure 70-10-71

Injector Signal - Testing (In-Line)

NOTE: Engine should be allowed to cool completely

1
before performing the following procedure.

The tool listed will be needed to the following procedure:

7313846 - Injector Signal Tester

MEL1563 or 7217666 - Remote Start Tool 2

WARNING
P115882

AVOID INJURY OR DEATH

Wear safety glasses to prevent eye injury when any
Remove the connector (Item 1) from the injector (Item 2)
of the following conditions exist:
[Figure 70-10-71].
• When fluids are under pressure.
• Flying debris or loose material is present.
Figure 70-10-72
• Engine is running.
• Tools are being used.
W-2019-0907 2

4
Open the rear door.

Remove the SCR. (See SCR Removal And Installation

on Page 70-30-8.) 1

NOTE: Ensure the battery is fully charged before 3

testing.

Figure 70-10-70

P127216

Install the signal tester (Item 1) to the harness connector

(Item 2) [Figure 70-10-72].

Install the signal tester connector (Item 3) to the injector

(Item 4) [Figure 70-10-72].
1
NOTE: Injector connector must be properly oriented
with tester connector or damage will occur.

Do not pull on wires or LED holder.

P115882
Connect the Remote Start Tool. (See REMOTE START
TOOL KIT - MEL1563 on Page 10-60-1.) or (See
Locate the fuel injectors (Item 1) [Figure 70-10-70]. REMOTE START TOOL (SERVICE TOOL) KIT -
7217666 on Page 10-61-1.)

828 of 1052 70-10-32 T870 Service Manual

ENGINE INFORMATION (CONT’D) If the signal tester light is on continuously or not at all,
there is an electrical malfunction.
Injector Signal - Testing (In-Line) (Cont’d)
Repeat the above procedure for the remaining injectors.
Figure 70-10-73

P-76439

Press the RUN button (Item 1) [Figure 70-10-73] on the

Remote Start Tool.

Figure 70-10-74

P127217

The signal tester light (Item 1) [Figure 70-10-74] should

flash once.

Press the START button (Item 2) [Figure 70-10-73] on

the Remote Start Tool.

The signal tester light (Item 1) [Figure 70-10-74] should

flash continuously.

To repeat the test, press the STOP button (Item 3)

[Figure 70-10-73] and wait one minute.

If the signal tester light flashes, the electrical system is

working.

829 of 1052 70-10-33 T870 Service Manual

830 of 1052 70-10-34 T870 Service Manual
ENGINE SPEED CONTROL (HAND) Figure 70-20-3

Removal And Installation

Figure 70-20-1 1
2

2
1 P107696

Remove the fastener (Item 1) and the two screws (Item 2)

P107184 [Figure 70-20-3] from the right side switch panel.

Figure 70-20-4
Remove the knob (Item 1) [Figure 70-20-1] from the
engine speed control.

Figure 70-20-2

1
P107697

Carefully remove the speed control decal (Item 1)

P107695 [Figure 70-20-6].

Remove the fastener (Item 1) and the screw (Item 2)

[Figure 70-20-2] from the right switch panel.

831 of 1052 70-20-1 T870 Service Manual

ENGINE SPEED CONTROL (HAND) (CONT’D)

Removal And Installation (Cont’d)

Figure 70-20-5

P107706

Remove the two screws (Item 1) [Figure 70-20-5].

Figure 70-20-6

P107475

Disconnect the electrical connector (Item 1) and remove

the engine speed control (Item 2) [Figure 70-20-6].

832 of 1052 70-20-2 T870 Service Manual

ENGINE SPEED CONTROL (FOOT) Figure 70-21-3

Removal And Installation

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

1 1
Figure 70-21-1

2 P106591

Remove the four bolts (Item 1) [Figure 70-21-3].

Lay the assembly down.

P106589
Figure 70-21-4

Remove the two mounting nuts (Item 1) from the right

side footrest (Item 2) [Figure 70-21-1].
2
Remove the footrest from the loader.

Figure 70-21-2
1

P107707
2
1
Disconnect the electrical connector (Item 1) from the
engine speed control (Item 2) [Figure 70-21-4].

Remove panel assembly from the loader.

P106590

NOTE: Mark the speed control foot pedal prior to

removal to aid in assembly.

Loosen the clamping bolt (Item 1) and remove the engine

speed control foot pedal (Item 2) [Figure 70-21-2].

Calibrate the foot throttle during installation. (See Foot

Throttle Calibration on Page 70-21-4.)

833 of 1052 70-21-1 T870 Service Manual

ENGINE SPEED CONTROL (FOOT) (CONT'D) Figure 70-21-7

Disassembly And Assembly

Figure 70-21-5

P107710

The pivot assemblies shown disassembled [Figure 70-

P-90755A 21-7].

Figure 70-21-8
Remove the two bolts (Item 1) and the snap ring (Item 2)
[Figure 70-21-5] from the engine speed control
assembly.

Figure 70-21-6

P107711

The engine speed control foot pedal pivot assembly

shown disassembled, [Figure 70-21-8] replace worn
P107709 parts as needed.

NOTE: No lubrication is necessary or recommended

Remove pivot bolt, nut (Item 1) and the spring (Item 2) on the engine speed control.
[Figure 70-21-6].

834 of 1052 70-21-2 T870 Service Manual

ENGINE SPEED CONTROL (FOOT) (CONT'D)

Disassembly And Assembly (Cont’d)

Figure 70-21-9

P107712

Remove the two screws (Item 1) and the engine speed

control (Item 2) [Figure 70-21-9].

Installation: Tighten the two screws (Item 1) [Figure 70-

21-9] to 2,26 - 2,60 N•m (20 - 23 in-lb) torque.

Figure 70-21-10

P107713

The engine speed control [Figure 70-21-10] shown

disassembled.

Align the tab (Item 1) with the slot (Item 2) [Figure 70-21-
10] during reassembly.

NOTE: After disassembly and assembly of the speed

control or replacement of the foot control
sensor, foot throttle calibration must be
performed. (See Foot Throttle Calibration on
Page 70-21-4.)

835 of 1052 70-21-3 T870 Service Manual

ENGINE SPEED CONTROL (FOOT) (CONT'D) Figure 70-21-13

Foot Throttle Calibration

Figure 70-21-11

1
NA3283

The alarm will beep four times and [FOOT] will appear in
NA3281 the display screen [Figure 70-21-13].

Figure 70-21-14
Diagnostic service code [M2899] will appear in the
display screen if the foot operated engine speed control
pedal requires calibration [Figure 70-21-11].
1
NOTE: Do not press the foot operated engine speed
control pedal until instructed. The calibration
procedure will fail and must be repeated if the
pedal is pressed partially or out of sequence.

Stop the engine.

Figure 70-21-12

P107096
1 1

Within ten seconds fully press and release the foot

operated speed control pedal (Item 1) [Figure 70-21-14].

NOTE: Pedal can be pressed multiple times.

P-90687A P-85307Y

Turn the key switch to RUN (Item 1) [Figure 70-21-12]

but do not start the engine.

Press and hold the auto idle button (Item 1) [Figure 70-
21-11] for five seconds.

836 of 1052 70-21-4 T870 Service Manual

ENGINE SPEED CONTROL (FOOT) (CONT'D)

Foot Throttle Calibration (Cont’d)

Figure 70-21-15

NA3267

The display screen will change to the hourmeter after

approximately five seconds [Figure 70-21-15].

NOTE: Do not attempt to start the engine or press the

foot operated engine speed control pedal
again until [FOOT] clears from the display
screen and the hourmeter appears. The
calibration procedure will fail and must be
repeated.

The calibration procedure is now complete. The loader

can be started or turn the key switch OFF.

The calibration can be repeated if necessary.

837 of 1052 70-21-5 T870 Service Manual

838 of 1052 70-21-6 T870 Service Manual
SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM

Description

The engine exhaust system is equipped with a selective catalytic reduction (SCR) system. The SCR is an emissions
reduction device that removes nitrogen oxides from the exhaust gases.

The SCR system consists of the dosing module, DCU (Dosing Control Unit) and other components. The DEF (Diesel
Exhaust Fluid) / AdBlue® is stored in the DEF / AdBlue® tank. Once it is needed, it is pressurized by the supply module
and is delivered to the dosing module under a certain level of pressure.

The machine will periodically perform a process to clean sulfur oxides from the SCR. This process is called DeSOX.

The SCR requires Diesel Exhaust Fluid (DEF) / AdBlue® to perform the DeSOX process.

NOTE: Diesel exhaust fluid (DEF) and AdBlue® are different names for the same fluid.

Figure 70-30-1

P121002A

839 of 1052 70-30-1 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM (CONT’D)

Diesel Exhaust Fluid (DEF) / AdBlue® Level

DEF /
ENGINE ENGINE
FLUID LEVEL ADBLUE® DISPLAY SERVICE
STAGE ALARM TORQUE RPM
LEVEL INDICATOR MALFUNCTION SCREEN CODES
DERATE DERATE
ICON

Four Green
Full
Lights
Three Green
75%
Lights
Two Green
50%
Lights
25% - One Green E00524617
Warning On DEF L [1] Three Beeps
10% Light U00176115
Three Beeps
E00524615
Less Than One Yellow (Additional
Level 1 On DEF L [1] E00524617 25%
10% Light beep every 20
U00176115
minutes)
Three Beeps
E00524615
for each code
Less Than One Red E00524616
Level 2 On DEF L [2] (Additional 50% 60%
5% Light E00524617
beep every 10
U00176115
minutes)
Three Beeps E00524600
for each code E00524616
Less Than One Red Low Idle
Final Flashing DEF L (Additional E00524617
2.5% Light Only
beep every 2 U00176101
minutes) U00176116

[1] Pressing the information button on the left panel will return the display to the hourmeter for 20 minutes.
[2] Pressing the information button on the left panel will return the display to the hourmeter for 10 minutes.

NOTE: The level indicator, DEF / AdBlue® malfunction icon, and display screen are located on the left panel. (See
Left Panel on Page 60-50-1.)

840 of 1052 70-30-2 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM (CONT’D)

DeSOX Process

There are three DeSOX processes:

• Passive DeSOX (Automatically performed by the machine unless inhibited)

• Forced DeSOX (Machine requested; operator initiated)

• Inhibit DeSOX (Option)

—————————————————————————————————————————————————————

Passive DeSOX Process Forced DeSOX Process

Figure 70-30-2 The machine may request a forced DeSOX if a passive

DeSOX was not finished.

Figure 70-30-3

NA3288

The DeSOX process will begin automatically every 200

NA3289
hours. The alarm will beep once and [DESOX] will
appear in the data display [Figure 70-30-2].
The alarm will beep twice, the engine malfunction icon
The display will revert to the hourmeter when the process will light, and [DESOX] will flash in the data display
is finished or press the information button to return to the [Figure 70-30-3]. Service code [E00008107] will also be
hourmeter immediately. displayed. The engine control unit (ECU) will reduce
engine torque by 40%.
The DeSOX process can last 15 minutes or longer.
The operator must turn the engine speed control to the
It is recommended to continue operating the machine high idle position. Keep the engine speed control in the
under load until the DeSOX process is finished. high idle position until the process is finished.

If the machine is turned OFF during a passive DeSOX The forced DeSOX process will last 20 minutes.
process, the process will resume the next time the
machine is started after acceptable conditions are It is recommended to continue operating the machine
reached. under load until the DeSOX process is finished.

841 of 1052 70-30-3 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM (CONT’D)

DeSOX Process (Cont’d)

Inhibit DeSOX Process (Option)

An optional kit is available to prevent the machine from performing a DeSOX process.

Figure 70-30-4 Figure 70-30-5

NA3289

The engine malfunction icon will light [Figure 70-30-5]

NA3302
and the alarm will beep twice if a DeSOX process is
needed while inhibited. Service code [E00008107] will
Press the bottom of the DeSOX Inhibit switch (Right also be displayed. The engine torque will reduce by 40%
Switch Panel) [Figure 70-30-4] to prevent the loader if the operator continues to operate the machine while
from performing a DeSOX process. The switch will light inhibited.
while DeSOX is inhibited. The inhibit will reset when the
machine is turned OFF.

Press and hold the bottom of the DeSOX Inhibit switch for
approximately 5 seconds to permanently prevent the
loader from performing a DeSOX process. The switch will
light while DeSOX is inhibited. Press and release the
bottom of the DeSOX Inhibit switch to reset and allow the
machine to perform a DeSOX process.

If a DeSOX process has started, pressing and holding

the bottom of the DeSOX Inhibit switch for 3 seconds will
stop the process.

842 of 1052 70-30-4 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM (CONT’D)

SCR System Codes

The following SCR system codes alert the operator of conditions that require attention. Continued operation of the machine
under these conditions will result in reduced machine performance.

Diesel Exhaust Fluid (DEF) / AdBlue® Unsatisfactory EGR Impeded

Quality
Figure 70-30-8
Figure 70-30-6

NA3305
NA3303

[EGR] will appear in the data display [Figure 70-30-8] to

[DEF Q] will appear in the data display [Figure 70-30-6] alert the operator that the exhaust gas recirculation
to alert the operator that the DEF / AdBlue® quality is (EGR) system is impeded. (See EGR Impeded on Page
unsatisfactory. (See Diesel Exhaust Fluid (DEF) / 70-30-7.)
AdBlue® Unsatisfactory Quality on Page 70-30-6.)
Diesel Exhaust Fluid (DEF) / AdBlue® Dosing
SCR System Component Tampering Interruption

Figure 70-30-7 Figure 70-30-9

NA3304 NA3306

[SCR] will appear in the data display [Figure 70-30-7] to [DOSE] will appear in the data display [Figure 70-30-9]
alert the operator that an SCR system component has to alert the operator that there has been an interruption in
been tampered with. (See SCR System Component DEF / AdBlue® dosing. (See Diesel Exhaust Fluid (DEF)
Tampering on Page 70-30-6.) / AdBlue® Dosing Interruption on Page 70-30-7.)

843 of 1052 70-30-5 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM (CONT’D)

Diesel Exhaust Fluid (DEF) / AdBlue® Unsatisfactory Quality

The machine can detect unsatisfactory quality DEF / AdBlue® and will alert the operator.

ENGINE ENGINE ENGINE

DISPLAY SERVICE
STAGE MALFUNCTION ALARM TORQUE RPM
SCREEN CODES
ICON DERATE DERATE

Warning On DEF Q [1] Three Beeps E00524624 [3]

Three Beeps (Additional
Level 1 Flashing DEF Q [1] E00524624 [3] 25%
beep every 20 minutes)
Three Beeps (Additional
Level 2 Flashing DEF Q [2] E00524624 [3] 50% 60%
beep every 10 minutes)
Three Beeps (Additional Low Idle
Final Flashing DEF Q E00524624 [3]
beep every 2 minutes) Only

[1] Pressing the information button on the left panel will return the display to the hourmeter for 20 minutes.
[2] Pressing the information button on the left panel will return the display to the hourmeter for 10 minutes.
[3] Also code U00351600, U00351601, or U00351631 will be displayed.

NOTE: The engine malfunction icon and display screen are located on the left panel. (See Left Panel on Page 60-
50-1.)

SCR System Component Tampering

The machine can detect tampering with SCR system components and will alert the operator.

ENGINE ENGINE ENGINE

DISPLAY SERVICE
STAGE MALFUNCTION ALARM TORQUE RPM
SCREEN CODES
ICON DERATE DERATE

Warning On SCR [1] Three Beeps E00524625 [3]

Three Beeps (Additional
Level 1 Flashing SCR [1] E00524625 [3] 25%
beep every 20 minutes)
Three Beeps (Additional
Level 2 Flashing SCR [2] E00524625 [3] 50% 60%
beep every 10 minutes)
Three Beeps (Additional Low Idle
Final Flashing SCR E00524625 [3]
beep every 2 minutes) Only

[1] Pressing the information button on the left panel will return the display to the hourmeter for 20 minutes.
[2] Pressing the information button on the left panel will return the display to the hourmeter for 10 minutes.
[3] One or more ‘U’ codes could also be displayed.

NOTE: The engine malfunction icon and display screen are located on the left panel. (See Left Panel on Page 60-
50-1.)

844 of 1052 70-30-6 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM (CONT’D)

EGR Impeded

The machine can detect an impeded exhaust gas recirculation (EGR) system and will alert the operator.

ENGINE ENGINE ENGINE

DISPLAY SERVICE
STAGE MALFUNCTION ALARM TORQUE RPM
SCREEN CODES
ICON DERATE DERATE

Warning On EGR [1] Three Beeps E00524621 [3]

Three Beeps (Additional
Level 1 Flashing EGR [1] E00524621 [3] 25%
beep every 20 minutes)
Three Beeps (Additional
Level 2 Flashing EGR [2] E00524621 [3] 50% 60%
beep every 10 minutes)
Three Beeps (Additional Low Idle
Final Flashing EGR E00524621 [3]
beep every 2 minutes) Only

[1] Pressing the information button on the left panel will return the display to the hourmeter for 20 minutes.
[2] Pressing the information button on the left panel will return the display to the hourmeter for 10 minutes.
[3] Also code U06522621. Additional ‘E’ codes could also be displayed.

NOTE: The engine malfunction icon and display screen are located on the left panel. (See Left Panel on Page 60-
50-1.)

Diesel Exhaust Fluid (DEF) / AdBlue® Dosing Interruption

The machine can detect an interruption in DEF / AdBlue® dosing and will alert the operator.

ENGINE ENGINE ENGINE

DISPLAY SERVICE
STAGE MALFUNCTION ALARM TORQUE RPM
SCREEN CODES
ICON DERATE DERATE

Warning On DOSE [1] Three Beeps E00524622 [3]

Three Beeps (Additional
Level 1 Flashing DOSE [1] E00524622 [3] 25%
beep every 20 minutes)
Three Beeps (Additional
Level 2 Flashing DOSE [2] E00524622 [3] 50% 60%
beep every 10 minutes)
Three Beeps (Additional Low Idle
Final Flashing DOSE E00524622 [3]
beep every 2 minutes) Only

[1] Pressing the information button on the left panel will return the display to the hourmeter for 20 minutes.
[2] Pressing the information button on the left panel will return the display to the hourmeter for 10 minutes.
[3] One or more ‘U’ codes could also be displayed.

NOTE: The engine malfunction icon and display screen are located on the left panel. (See Left Panel on Page 60-
50-1.)

845 of 1052 70-30-7 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Figure 70-30-11
(CONT’D)

SCR Removal And Installation

2

WARNING
HOT SURFACES CAN CAUSE SERIOUS INJURY
• Do not touch. 1
• Allow to cool before servicing.
W-2533-1012

P115863
Open the rear door.

Remove the rear grille and side panels. (See Removing Loosen the nut (Item 1) and remove the clamp (Item 2)
on Page 50-60-1.) [Figure 70-30-11].

Drain the engine coolant from the cooling system. (See Installation: Tighten the nut to 8 - 10 N•m (71 - 89 in-lb)
Removing And Replacing Coolant on Page 10-90-5.) torque.
NOTE: It is recommended that any clamps be
replaced with new if removed during service. Figure 70-30-12

Always use new gaskets when servicing.

Figure 70-30-10

1
1

2
1 1

P115864

Disconnect the right side temperature sensor connector

(Item 1) [Figure 70-30-12].
P121249

Remove the four bolts (Item 1) and the engine cover

(Item 2) [Figure 70-30-10].

846 of 1052 70-30-8 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Figure 70-30-15
(CONT’D)

SCR Removal And Installation (Cont’d)

Figure 70-30-13 1

1
1 P120664
2

Disconnect the metering valve connector (Item 1)

[Figure 70-30-15].
P115865
Figure 70-30-16

Remove the four nuts and bolts (Item 1) from the SCR
mount bracket (Item 2) [Figure 70-30-13].

Installation: If the nuts (Item 3) [Figure 70-30-13] are

loosened torque to 8 - 10 N•m (71 - 89 in-lb) torque.

Figure 70-30-14

1
P115867

Remove the NOx sensor (Item 1) [Figure 70-30-16] and

move it aside.

NOTE: When the Downstream and Upstream NOx

sensors are both removed mark the sensors
P115866 for correct installation into the SCR or DOC.

Use anti-seize when replacing or reinstalling

Disconnect the temperature sensor (Item 1) [Figure 70- temperature and NOx sensors.
30-14]. (if equipped)
Installation: Tighten the NOx sensor to 40 - 60 N•m (30 -
NOTE: The outlet temperature sensor and sensor port 44 ft-lb) torque.
have been removed on later model machines.

847 of 1052 70-30-9 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Dosing Module Removal And Installation
(CONT’D)
Figure 70-30-18
SCR Removal And Installation (Cont’d)

Figure 70-30-17
1 2
1

1
P121170
2

P115868 Remove the three bolts (Item 1) and the dosing module
(Item 2) [Figure 70-30-18].

Remove the two coolant lines (Item 1) and remove the Figure 70-30-19
DEF / Adblue® line (Item 2) [Figure 70-30-17].

NOTE: Coolant lines must be hooked up correctly.

1
Remove the SCR from the engine.

P121175A

Inspect the dosing module for damage and replace if

necessary (Item 1) [Figure 70-30-19].

Replace the gasket (Item 2) [Figure 70-30-19].

848 of 1052 70-30-10 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Figure 70-30-20
(CONT’D)
1
Dosing Control Unit (DCU) Removal And Installation
1

DANGER
2

P121171

P-90328
Remove the four bolts (Item 1) and relocate the bracket
AVOID DEATH
(Item 2) [Figure 70-30-20].
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
Figure 70-30-21
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm 2
support. Replace if damaged. 1
D-1009-0409

WARNING 4

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. P121172
W-2059-0598

Disconnect the wire harness (Item 1), the ground

Raise the lift arms and install an approved lift arm connection (Item 2) and the sensor connector (Item 3)
support device. (See Installing on Page 10-20-2.) [Figure 70-30-21].

Raise the operator cab. (See Raising on Page 10-30-1.) Remove the tie strap (Item 4) [Figure 70-30-21].

849 of 1052 70-30-11 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Figure 70-30-24
(CONT’D)

Dosing Control Unit (DCU) Removal And Installation 2 1

(Cont’d)

Figure 70-30-22

1
1

2 P121178

1 Remove the nuts and bolts (Item 1). Remove the DCU
from the bracket (Item 2) [Figure 70-30-24].

P121173

Remove the DCU bracket mounting nuts and bolts (Item

1) [Figure 70-30-22] from the left fender.

Remove the DCU from the loader.

Figure 70-30-23

3
2

1
1

P121177

Remove the mounting bolts (Item 1) and the DCU (Item

2) from the bracket (Item 3) [Figure 70-30-23].

850 of 1052 70-30-12 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Figure 70-30-25
(CONT’D)

Supply Module Removal And Installation

DANGER 2

P121186

P-90328
Push down on the retaining clip (Item 1) and remove the
AVOID DEATH
wire harness (Item 2) [Figure 70-30-25].
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
Figure 70-30-26
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
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 1
support device can allow the lift arms or attachment
to fall and cause injury or death. P121185
W-2059-0598

Remove the three nuts and bolts (Item 1) [Figure 70-30-

Raise the lift arms and install an approved lift arm 26] from the left fender.
support device. (See Installing on Page 10-20-2.)
Installation: Tighten the three nuts and bolts (Item 1)
Raise the operator cab. (See Raising on Page 10-30-1.) [Figure 70-30-26] to 17,0 - 21,0 N•m (12.5 - 15.5 ft-lb)
torque.

851 of 1052 70-30-13 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Supply Module Filter Removal And Installation
(CONT’D)
Figure 70-30-28
Supply Module Removal And Installation (Cont’d)

Figure 70-30-27
2

2
1

P121225

P121176 Remove the filter cover (Item 1) from the supply module
(Item 2) [Figure 70-30-28].

Remove the inlet hose (Item 1), outlet hose (Item 2) and Installation: Tighten the filter cover (Item 1) [Figure 70-
the return hose (Item 3) [Figure 70-30-27] from the 30-28] to 20,0 N•m (15.0 ft-lb) torque.
supply module.
Figure 70-30-29
Remove the supply module from the loader.

P121226

Remove the equalizer element (Item 1) [Figure 70-30-

29].

852 of 1052 70-30-14 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Figure 70-30-32
(CONT’D)

Supply Module Filter Removal And Installation

(Cont’d)

Figure 70-30-30

P121228

Rotate the filter removal tool clockwise as shown (Item 1)

[Figure 70-30-32].

P121231 Figure 70-30-33

Use the filter removal tool (7267635) [Figure 70-30-30]

to aid in the removal of the filter.

Figure 70-30-31

1 P121230

Remove the filter (Item 1) [Figure 70-30-33].

Install new filter and equalizer element.

P121227

Insert the filter removal tool (Item 1) [Figure 70-30-31]

into the filter till it clips on guide.

853 of 1052 70-30-15 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Figure 70-30-34
(CONT’D)

Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal

And Installation (Earlier Models)

1
DANGER 3

P121191

P-90328 Remove the bolt and nut (Item 1) [Figure 70-30-34].

AVOID DEATH
Remove the two bolts (Item 2) and the duct panel (Item 3)
• Disconnecting or loosening any hydraulic
[Figure 70-30-34].
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Figure 70-30-35
• 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

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 P121192

Raise the lift arms and install an approved lift arm Remove the bolts (Item 1) and the outlet screen (Item 2)
support device. (See Installing on Page 10-20-2.) [Figure 70-30-35].

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

Remove the lower fan duct. (See Lower Fan Duct

Removal And Installation on Page 70-60-4.)

Drain the engine coolant from the cooling system. (See

Removing And Replacing Coolant on Page 10-90-5.)

854 of 1052 70-30-16 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Figure 70-30-38
(CONT’D)

Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal

And Installation (Earlier Models) (Cont’d)

Figure 70-30-36

1 1 2
1
2
P121198A

1 Remove the nut (Item 1) and loosen the nut and bolt
(Item 2) [Figure 70-30-38].

P121193 Installation: Torque the nut to 2,8 - 3,1 N•m (25 - 27 in-
lb) torque.

Remove the three nuts and bolts (Item 1) from the fill tube Figure 70-30-39
mount bracket (Item 2) [Figure 70-30-36].

Installation: Torque the nuts and bolts (Item 1) [Figure

70-30-36] to 11 N•m (100 in-lb) torque.

Figure 70-30-37

2 1
1
3

2 P121196A

Reposition the hold down strap (Item 1) [Figure 70-30-

39].

P121194

Mark and disconnect the coolant lines (Item 1) and the

DEF / AdBlue® lines (Item 2) [Figure 70-30-37].

Disconnect the wire harness (Item 3) [Figure 70-30-37].

NOTE: Coolant lines must be hooked up correctly or

the fluid may not thaw properly and result in
an error code and engine derate.

855 of 1052 70-30-17 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM
(CONT’D)

Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal

And Installation (Earlier Models) (Cont’d)

Figure 70-30-40

1
1

P121195A

Remove the bolts (Item 1) and reposition the bracket

(Item 2) [Figure 70-30-40].

Remove the DEF / AdBlue® tank from the loader.

Installation: Tighten the bolts to 9,5 N•m (84 in-lb)

torque.

856 of 1052 70-30-18 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Figure 70-30-41
(CONT’D)

Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal

And Installation (Later Models)

1
DANGER 3

P121191

P-90328 Remove the bolt and nut (Item 1) [Figure 70-30-41].

AVOID DEATH
Remove the two bolts (Item 2) and the duct panel (Item 3)
• Disconnecting or loosening any hydraulic
[Figure 70-30-41].
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Figure 70-30-42
• 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

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 P121192

Raise the lift arms and install an approved lift arm Remove the bolts (Item 1) and the outlet screen (Item 2)
support device. (See Installing on Page 10-20-2.) [Figure 70-30-42].

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

Remove the lower fan duct. (See Lower Fan Duct

Removal And Installation on Page 70-60-4.)

Drain the engine coolant from the cooling system. (See

Removing And Replacing Coolant on Page 10-90-5.)

857 of 1052 70-30-19 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Figure 70-30-45
(CONT’D)

Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal

And Installation (Later Models) (Cont’d)

Figure 70-30-43

1 1
1
2
P127570

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

70-30-45].

P121193 Reposition the strap.

Installation: Torque the nut to 2,8 - 3,1 N•m (25 - 27 in-

Remove the three nuts and bolts (Item 1) from the fill tube lb) torque.
mount bracket (Item 2) [Figure 70-30-43].
Figure 70-30-46
Installation: Torque the nuts and bolts (Item 1) [Figure
70-30-43] to 11 N•m (100 in-lb) torque.
2
Figure 70-30-44

1 2 1

1
1 2

P127573

Remove the bolts (Item 1) and reposition the bracket

P127571 (Item 2) [Figure 70-30-46].

Installation: Tighten the bolts to 9,5 N•m (84 in-lb)

Mark and disconnect the coolant lines (Item 1) and the torque.
DEF / AdBlue® lines (Item 2) [Figure 70-30-44].

NOTE: Coolant lines must be hooked up correctly or

the fluid may not thaw properly and result in
an error code and engine derate.

858 of 1052 70-30-20 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Diesel Exhaust Fluid (DEF) / AdBlue® Sensor
(CONT’D) Removal And Installation (Later Models)

Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal Figure 70-30-49

And Installation (Later Models) (Cont’d)

Figure 70-30-47 2
1

1 2

P127571

P127576 Mark and disconnect the coolant lines (Item 1) and the
DEF / AdBlue® lines (Item 2) [Figure 70-30-49].

Remove the bolts (Item 1) [Figure 70-30-47]. NOTE: Coolant lines must be hooked up correctly or
the fluid may not thaw properly and result in
Figure 70-30-48 an error code and engine derate.

Figure 70-30-50

1
1
P127574

P127573
Disconnect the wire harness (Item 1) from the DEF
sensor (Item 2) [Figure 70-30-48].
Remove the six screws (Item 1) [Figure 70-30-50].
Remove the DEF sensor and DEF / AdBlue® tank from
the loader. NOTE: To avoid contamination, throughly clean the
tank and sensor assembly before removal.

859 of 1052 70-30-21 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Figure 70-30-53
(CONT’D)

Diesel Exhaust Fluid (DEF) / AdBlue® Sensor 1

Removal And Installation (Later Models) (Cont’d)

Figure 70-30-51

1 1

1 NA12776B

Remove the four nuts and bolts (Item 1) from the sensor
mount (Item 2) [Figure 70-30-53].

P127576 Installation: Tighten the bolts to 7,6 - 8,4 N•m (67 - 73

in-lb) torque.

Remove the mounting bolts (Item 1) [Figure 70-30-51]. Remove the DEF sensor assembly from the loader.

Figure 70-30-52

1
P127574

Disconnect the wire harness (Item 1) from the DEF

sensor (Item 2) [Figure 70-30-52].

Remove the DEF sensor.

860 of 1052 70-30-22 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Figure 70-30-54
(CONT’D)

Diesel Exhaust Fluid (DEF) / AdBlue® Coolant Valve

Removal And Installation

1
DANGER 3

P121191

P-90328 Remove the bolt and nut (Item 1) [Figure 70-30-54].

AVOID DEATH
Remove the two bolts (Item 2) and the duct panel (Item 3)
• Disconnecting or loosening any hydraulic
[Figure 70-30-54].
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
Figure 70-30-55
• 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

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 P121192

Raise the lift arms and install an approved lift arm Remove the bolts (Item 1) and the outlet screen (Item 2)
support device. (See Installing on Page 10-20-2.) [Figure 70-30-55].

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

Drain the engine coolant from the cooling system. (See

Removing And Replacing Coolant on Page 10-90-5.)

861 of 1052 70-30-23 T870 Service Manual

SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Figure 70-30-58
(CONT’D)

Diesel Exhaust Fluid (DEF) / AdBlue® Coolant Valve

Removal And Installation (Cont’d)

Figure 70-30-56 1

2
3
3 2
1
4 P121232

Remove the bolts (Item 1) and the tie straps (Item 2)

[Figure 70-30-58].

P121223 Remove the clamp / hose (Item 3) and the coolant valve
(Item 4) [Figure 70-30-58].

Disconnect the coolant valve wire harness (Item 1) Figure 70-30-59

[Figure 70-30-56].

Figure 70-30-57
1

1 1

P121233

P121224 Note the flow arrow (Item 1) [Figure 70-30-59] during

assembly.

Remove the mounting nuts (Item 1) [Figure 70-30-57].

862 of 1052 70-30-24 T870 Service Manual

DIESEL OXIDATION CATALYST (DOC) Figure 70-40-2

Removal And Installation

WARNING
2
HOT SURFACES CAN CAUSE SERIOUS INJURY 1
• Do not touch.
• Allow to cool before servicing.
W-2533-1012

Open the rear door. P115876

Remove the SCR catalyst. (See SCR Removal And

Installation on Page 70-30-8.) Loosen the clamp (Item 1) and the DOC mount clamps
(Item 2) [Figure 70-40-2]. Reposition the clamps.
NOTE: It is recommended that any clamps be
replaced with new if removed during service. Installation: Tighten the clamp (Item 1) [Figure 70-40-2]
to 8 - 10 N•m (71 - 89 in-lb) torque.
Always use new gaskets when servicing.
Installation: Tighten the DOC mount clamps (Item 2)
Figure 70-40-1 [Figure 70-40-2] to 11 - 13 N•m (97 - 115 in-lb) torque.

Figure 70-40-3

1
2

P115875

P115877
Disconnect the temperature sensor (Item 1) (if equipped)
and remove the NOx sensor (Item 2) [Figure 70-40-1].
Lift the DOC (Item 1) [Figure 70-40-3] up and out of the
NOTE: When the downstream and upstream NOx engine compartment.
sensors are both removed mark the sensors
for correct installation into the SCR or DOC.

Use anti-seize when replacing or reinstalling

temperature and NOx sensors.

Installation: Tighten the NOx sensor to 40 - 60 N•m (30 -

44 ft-lb) torque.

863 of 1052 70-40-1 T870 Service Manual

864 of 1052 70-40-2 T870 Service Manual
AIR CLEANER Figure 70-50-3

Housing Removal And Installation

Remove the rear grille from the loader. (See Removing 1

on Page 50-60-1.) 1

Raise the lift arms and install an approved lift arm

support device. (See Installing on Page 10-20-2.)
Figure 70-50-1

1
1

1 P115859

Remove the four bolts (Item 1) [Figure 70-50-3] from the

air cleaner assembly.

3 Figure 70-50-4

2
P115857A
1

Mark and disconnect the wire harnesses (Item 1) [Figure

70-50-1].

Remove the two bolts (Item 2) and move the NOx

brackets (Item 3) [Figure 70-50-1] to the side.

Figure 70-50-2

P121298

Remove the air cleaner (Item 1) [Figure 70-50-4] from

1 the loader.

P115858A

Loosen the hose clamp (Item 1) [Figure 70-50-2] and

disconnect the hose from the air cleaner.

Disconnect the wire harness (Item 2) [Figure 70-50-2]

from the air cleaner sender.

865 of 1052 70-50-1 T870 Service Manual

866 of 1052 70-50-2 T870 Service Manual
ENGINE COOLING SYSTEM Figure 70-60-1

Radiator / Oil Cooler Removal And Installation

Stop the engine and open the rear door. 1

Allow engine to cool.

Remove the rear grille and side panels. (See Removing

on Page 50-60-1.)

Remove the SCR. (See SCR Removal And Installation

on Page 70-30-8.)

Drain the coolant. (See Removing And Replacing

Coolant on Page 10-90-5.) P115888A

Remove the air filter housing. (See Housing Removal

And Installation on Page 70-50-1.) Disconnect and plug the radiator air bleed hose (Item 1)
[Figure 70-60-1].
Drain the hydraulic fluid. (See Removing And Replacing
Hydraulic Fluid on Page 10-120-2.) Figure 70-60-2

WARNING
AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned. 2
W-2070-1203 1

P115890

Disconnect the radiator hose (Item 1) and the coolant

tank fill hose (Item 2) [Figure 70-60-2].

867 of 1052 70-60-1 T870 Service Manual

ENGINE COOLING SYSTEM (CONT'D) Figure 70-60-5

Radiator / Oil Cooler Removal And Installation

(Cont'd)

Figure 70-60-3
2 1

P115891A

Remove the bolt (Item 1) and reposition the fuel cooler

(Item 2) [Figure 70-60-5].
P115892A
Figure 70-60-6

Disconnect the left charge air hose (Item 1) [Figure 70-

60-3].

Figure 70-60-4

1
1

P121309

Disconnect the radiator hose (Item 1) [Figure 70-60-6].

P121242

Disconnect the right charge air hose (Item 1) [Figure 70-

60-4].

868 of 1052 70-60-2 T870 Service Manual

ENGINE COOLING SYSTEM (CONT'D)

Radiator / Oil Cooler Removal And Installation

(Cont'd) IMPORTANT
Figure 70-60-7 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

Figure 70-60-8

1 1

P115896A

1
Remove radiator hold-down bolts (Item 1) [Figure 70-60-
7].

P115895

Disconnect the hydraulic hose (Item 1) [Figure 70-60-8]

both sides.

Lift the radiator / oil cooler up and remove it from the

loader.

869 of 1052 70-60-3 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Hydraulic Reversing Fan Description

Hydraulic Fan Description This machine may be equipped with a Reversing Fan.

The proportional relief valve meters the flow through the The function of the reversing fan is to clear dust and
fan motor. The valve receives signals from the controller debris from the rear grille. This is accomplished by
which gathers information from both the engine and reversing the direction of the cooling fan for several
hydraulic temperature sensors. seconds.

The hydraulic fan is used to cool the engine and hydraulic A reversing cycle consists of the following steps and
/ hydrostatic systems. The hydraulic fan consists of a fan takes about 16 seconds total.
and hydraulic motor that is controlled by a proportional
1. Flow to the rotating group is ramped down.
relief valve.
2. Reversing valve shifts, switching inlet and outlet ports.
NOTE: The proportional relief valve is factory set and
is not adjustable.
3. Flow to the rotating group is ramped up, spinning the
fan in reverse direction. Full fan speed is held for about 3
The fan speed is determined by the engine coolant
seconds.
temperature and the hydraulic fluid temperature.
Depending on these temperatures the fan speed (rpm)
4. Flow to the rotating group is ramped down.
can range from 0 - 4000 rpm.
5. Reversing valve shifts back to neutral.
The hydraulic fan speed at cold engine startup will range
from 0 - 500 rpm until the engine coolant and the
6. Flow is ramped up and normal cooling is restored.
hydraulic fluid reach normal operating temperatures.
Reversing frequency varies from 30 to 5 minute intervals
depending on fluid temperature.
During normal operating temperatures the fan speed may
range from approximately 1900 - 3500 rpm.
NOTE: To protect vital systems, the fan will not
reverse when fluid temperatures are low
(below 60°F). To prevent overheating, the fan
will not reverse when fluid temperatures are
very high (engine coolant over 210°F, or
hydraulic fluid over 226°F in auto mode or
230°F in manual mode).

Lower Fan Duct Removal And Installation

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

Figure 70-60-9

P115884

Unhook the three rubber straps (Item 1) [Figure 70-60-9]

and remove lower fan duct.

870 of 1052 70-60-4 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 70-60-11

Hydraulic Fan Motor Assembly Removal And

Installation

Standard Models
1
2

IMPORTANT 4 4

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 3
tubelines and ports to keep dirt out. Dirt can quickly
P115778A
damage the system.
I-2003-0888
Remove the fan motor inlet hose (Item 1) and outlet hose
Figure 70-60-10 (Item 2) [Figure 70-60-11].

Remove the charge pressure tubeline (Item 3) [Figure

70-60-11].

1 Disconnect the electrical connectors (Item 4) [Figure 70-

60-11].

Figure 70-60-12

1 1
P115777

Remove the fan case drain hose (Item 1) [Figure 70-60-

10] from the back of the fan motor assembly.

2 P115776

Remove the four nuts (Item 1) [Figure 70-60-12].

Remove fan assembly (Item 2) [Figure 70-60-12].

NOTE: The fan mounting nuts are a single use part

and should be replaced whenever the nuts are
removed.

871 of 1052 70-60-5 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 70-60-15

Hydraulic Fan Motor Assembly Removal And

Installation (Cont’d)

Reversing Models

Figure 70-60-13
1

3 3
1 4

P128987

Disconnect both electrical connectors (Item 1) [Figure

2 70-60-15].

Figure 70-60-16
P127582

Remove the fan motor inlet hose (Item 1), charge

pressure tubeline (Item 2) and the case drain hoses (Item
3) [Figure 70-60-13].
1 1
Disconnect the electrical connector (Item 4) [Figure 70-
60-13].

Figure 70-60-14

2 P115776

Remove the four nuts (Item 1) [Figure 70-60-16].

1 NOTE: The fan mounting nuts are a single use part

and should be replaced whenever they are
removed.

Remove the hydraulic fan motor assembly (Item 2)

[Figure 70-60-16].
P128986

Remove the fan motor outlet hose (Item 1) [Figure 70-

60-14].

Cap and plug all hoses and fittings.

872 of 1052 70-60-6 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 70-60-19

Hydraulic Fan Motor Removal And Installation

2
All Models 2

Figure 70-60-17
3
1
1

P115642A

Use the following procedure to remove the fan hub from

the fan motor shaft:
1
Install a bushing (Item 1) [Figure 70-60-19] in the hub to
P115692A
protect the fan motor shaft and threads during removal.

Remove the four bolts (Item 1) and the cover plate (Item Use two bolts (Item 2) to position a puller (Item 3) on the
2) [Figure 70-60-17]. bushing (Item 1) as shown [Figure 70-60-19].

Installation: Tighten the bolts 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 70-60-18 Tighten the bolts and strike the puller with a hammer to
loosen the hub from the motor shaft.

Figure 70-60-20

1
2 2

P115641

1
Remove the nut (Item 1) [Figure 70-60-18] from the P115643
motor shaft.

Installation: Tighten the nut to 61 - 74 N•m (45 - 55 ft-lb) Remove and discard the two nuts and cotter pins (Item 1)
torque. [Figure 70-60-20].

Remove the two washers (Item 2) [Figure 70-60-20].

Installation: Tighten the nuts to 10,2 N•m (7.5 ft-lb)

torque.

873 of 1052 70-60-7 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Hydraulic Fan Motor Disassembly And Assembly

Hydraulic Fan Motor Removal And Installation Standard Model

(Cont’d)
Figure 70-60-22
All Models (Cont’d)

Figure 70-60-21

P115320

P115644 Remove the filter (Item 1) [Figure 70-60-22].

Installation: Lubricate threads and filter O-ring prior to

Remove and discard the two bolts (Item 1) [Figure 70- installation. Tighten the filter (Item 1) [Figure 70-60-22]
60-21] then remove motor. to 37 - 45 N•m (27 - 33 ft-lb) torque.

Installation: Tighten the bolts to 10,2 N•m (7.5 ft-lb) Figure 70-60-23
torque.

NOTE: Always install new bolts, nuts, cotter pins,

and rubber gasket when installing the fan
motor.

1
P115321A

Remove coil mounting nut (Item 1), the coil (Item 2), and
the proportional valve (Item 3) [Figure 70-60-23].

Installation: Tighten the proportional valve (Item 3)

[Figure 70-60-23] to 28 - 34 N•m (21 - 25 ft-lb) torque.

Installation: Tighten the coil mounting nut (Item 1)

[Figure 70-60-23] to 7 - 9 N•m (5 - 7 ft-lb) torque.

874 of 1052 70-60-8 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 70-60-26

Hydraulic Fan Motor Disassembly And Assembly

(Cont’d)

Standard Model (Cont’d)

Figure 70-60-24

1
1

P-76726

2 2 Replace the O-ring (Item 1) [Figure 70-60-26].

Figure 70-60-27

P115322

Replace the O-rings (Item 1) and back-up rings (Item 2)

1
[Figure 70-60-24]. 2
3
Figure 70-60-25

P115328

1 Remove and inspect the fitting (Item 1), the spring (Item
2), and the check valve (Item 3) [Figure 70-60-27] for
damage and replace as needed.

Installation: Install a new O-ring (Item 4) [Figure 70-60-

P115323A 27] and lubricate with oil before installing.

Remove the pressure transducer (Item 1) [Figure 70-60-

25].

Installation: Tighten the pressure transducer (Item 1)

[Figure 70-60-25] to 10 N•m (88 in-lb) torque.

875 of 1052 70-60-9 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Reversing Model

Hydraulic Fan Motor Disassembly And Assembly Figure 70-60-30

(Cont’d)

Standard Model (Cont’d)

Figure 70-60-28 1

1 P128972

Remove the filter (Item 1) [Figure 70-60-30].

P115329 Installation: Lubricate threads and filter O-ring prior to

installation. Tighten the filter to 37 - 45 N•m (27 - 33 ft-lb)
torque.
Remove the four bolts (Item 1) [Figure 70-60-28].
Figure 70-60-31
Installation: Tighten the bolts (Item 1) [Figure 70-60-28]
to 37 - 45 N•m (27 - 33 ft-lb) torque.

NOTE: Note the fan motor to filter adapter alignment

to ensure correct assembly.

Figure 70-60-29
3
2
1 2

P128974

Remove coil mounting nut (Item 1), the coil (Item 2), and
3 the reversing valve (Item 3) [Figure 70-60-31].
4
Installation: Tighten the reversing valve (Item 3) [Figure
P115326 70-60-31] to 41 - 50 N•m (30 - 37 ft-lb) torque.

Installation: Tighten the coil mounting nut (Item 1)

Remove the fan motor (Item 1) from the filter adapter [Figure 70-60-31] to 4 N•m (3 ft-lb) torque.
(Item 2) [Figure 70-60-29].

Remove the seals (Item 3 and 4) [Figure 70-60-29].

To continue fan motor disassembly and assembly

(Standard Model) see [Figure 70-60-41 on Page 13].

876 of 1052 70-60-10 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 70-60-34

Hydraulic Fan Motor Disassembly And Assembly

(Cont’d) 1

Reversing Model (Cont’d)

Figure 70-60-32

P128977

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

2 2 2) [Figure 70-60-34].

Figure 70-60-35
P128976

Replace the four O-rings (Item 1) and six back-up rings

(Item 2) [Figure 70-60-32].

Figure 70-60-33

P115323A
3
2
Remove the pressure transducer (Item 1) [Figure 70-60-
35].

1 Installation: Tighten the pressure transducer to 10 N•m

P128975 (88 in-lb) torque.

Remove coil mounting nut (Item 1), the coil (Item 2), and
the proportional valve (Item 3) [Figure 70-60-33].

Installation: Tighten the proportional valve (Item 3)

[Figure 70-60-33] to 28 - 34 N•m (21 - 25 ft-lb) torque.

Installation: Tighten the coil mounting nut (Item 1)

[Figure 70-60-33] to 7 N•m (5 ft-lb) torque.

877 of 1052 70-60-11 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 70-60-38

Hydraulic Fan Motor Disassembly And Assembly

(Cont’d)

Reversing Model (Cont’d)

Figure 70-60-36

P128979

1 Remove the four bolts (Item 1) [Figure 70-60-38].

Installation: Tighten the bolts to 37 - 45 N•m (27 - 33 ft-

lb) torque.
P-76726
NOTE: Note the fan motor to filter adapter alignment
to ensure correct assembly.
Replace the O-ring (Item 1) [Figure 70-60-36].
Figure 70-60-39
Figure 70-60-37
1 2

1
3 2

4 3 4

P128980
P128978

Remove the fan motor (Item 1) from the filter adapter

Remove and inspect the fitting (Item 1), spring (Item 2) (Item 2) [Figure 70-60-39].
and the check valve (Item 3) [Figure 70-60-37] for
damage and replace as needed. Remove the seals (Item 3 and 4) [Figure 70-60-39].

Installation: Install a new O-ring (Item 4) [Figure 70-60-

37] and lubricate with oil before installing.

878 of 1052 70-60-12 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 70-60-42

Hydraulic Fan Motor Disassembly And Assembly

2
(Cont’d) 1

Reversing Model (Cont’d)

5
Figure 70-60-40

3
4
P115460

Remove the front cover (Item 1) from the pump housing

(Item 2) [Figure 70-60-42].
1

1 Remove the seals (Item 3 and 4) [Figure 70-60-42].

P128982
Remove the pump assemble (Item 5) [Figure 70-60-42].

Replace the O-rings on the three plugs (Item 1) [Figure Figure 70-60-43
70-60-40].

All Models

Figure 70-60-41

P115458

1 Inspect the condition of the gear faces and the mating

surfaces of the wear blocks [Figure 70-60-43]. If
P115457 excessive wear or damage is visible, replace the fan
motor.

Remove the two bolts (Item 1) and the slinger (Item 2) Check the bushings in the wear blocks [Figure 70-60-
[Figure 70-60-41]. 43]. If excessive wear is visible, replace the fan motor.

879 of 1052 70-60-13 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 70-60-46

Hydraulic Fan Motor Disassembly And Assembly

(Cont’d)
2
All Models (Cont’d) 1

Figure 70-60-44

1 2 3

P115460A

Install the pump assembly (Item 1) and the new seal

(Item 2) [Figure 70-60-46] in the housing.

NOTE: Orientation of the seals must be followed for

P115459 correct operation of the fan motor.

Figure 70-60-47
Remove the snap ring (Item 1), washer (Item 2) and the
seal (Item 3) [Figure 70-60-44].
3 1
Figure 70-60-45

2 1 3

2
P115476

Install a new black rubber seal (Item 1) with the channel

P115459 (Item 2) [Figure 70-60-47] of seal facing down and press
firmly into grove of casing.

Install a new washer (Item 1), snap ring (Item 2) and seal Press a new yellow plastic seal (Item 3) [Figure 70-60-
(Item 3) [Figure 70-60-45]. 47] firmly onto the black rubber seal.

880 of 1052 70-60-14 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 70-60-50

Hydraulic Fan Motor Disassembly And Assembly

(Cont’d)
1
All Models (Cont’d)

Figure 70-60-48

P115326A

Install a new seal (Item 1) [Figure 70-60-50] into the fan

motor.

1 NOTE: Orientation of the seals must be followed for

P115475A correct operation of the fan motor.

Figure 70-60-51
The ejector pads (Item 1) [Figure 70-60-48] on the
yellow plastic seal will be facing up.

NOTE: Verify that both seals are flush with the

surface of the housing. 1
2
Figure 70-60-49

P115430

Install a new black rubber seal (Item 1) with the channel

1 (Item 2) [Figure 70-60-51] of seal facing down and press
firmly into grove of casing.

P115457

Assemble the pump housing and the front cover. Install

the two bolts (Item 1) and install a new slinger (Item 2)
[Figure 70-60-49].

881 of 1052 70-60-15 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Blower Housing Removal And Installation

Hydraulic Fan Motor Disassembly And Assembly

(Cont’d)

All Models (Cont’d) IMPORTANT

Figure 70-60-52 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,
2 tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Remove the air conditioning condenser if equipped. (See

Removal And Installation on Page 80-60-1.)

Remove the radiator/oil cooler. (See Radiator / Oil Cooler

3 Removal And Installation on Page 70-60-1.)

Figure 70-60-54

P115432

Press a new yellow plastic seal (Item 1) firmly onto the

black rubber seal (Item 2) [Figure 70-60-52].

The ejector pads (Item 3) [Figure 70-60-52] on the

yellow plastic seal will be facing up.

NOTE: Verify that both seals are flush with the

surface of the housing. 1

Figure 70-60-53
P115776A

Push the blower housing (Item 1) [Figure 70-60-54] up

and remove the housing from the loader.

NOTE: Hydraulic fan assembly removed for photo

clarity.

P115329

Assemble the fan motor and the filter adapter. Install the
four bolts (Item 1) [Figure 70-60-53].

Installation: Tighten the four bolts (Item 1) [Figure 70-

60-53] to 37 - 45 N•m (27 - 33 ft-lb) torque.

882 of 1052 70-60-16 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Thermostat Housing Removal And Installation

Water Pump Removal And Installation Figure 70-60-57

Drain the fluid from the radiator. (See Removing And

Replacing Coolant on Page 10-90-5.)
1
Remove the alternator belt. (See Belt Replacement on
Page 60-30-1.)

Figure 70-60-55

2 2

1
P121040

Reposition the clamps (Item 1) and remove the hose

(Item 2) [Figure 70-60-57].

Figure 70-60-58

P121038 4

2
Remove the four bolts (Item 1) from the water pump
pulley (Item 2) [Figure 70-60-55].
3
Remove the water pump pulley (Item 2) [Figure 70-60-
55]

Disconnect the coolant hoses. 1

Figure 70-60-56

P121041

Reposition the clamps (Item 1) and remove the hose

(Item 2) [Figure 70-60-58].

Remove the four bolts (Item 3) and the thermostat

2 housing (Item 4) [Figure 70-60-58].

Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.

1
P121039

Remove the four bolts (Item 1) and the water pump (Item
2) [Figure 70-60-56].

Installation: Apply Loctite® 272 to the water pump

mounting bolts. Torque the bolts to 22 N•m (16 ft-lb).

883 of 1052 70-60-17 T870 Service Manual

ENGINE COOLING SYSTEM (CONT’D)

Thermostat - Testing

Figure 70-60-59

P121042

Place the thermostat and a thermometer in a container of

water. Gradually heat the water and inspect the operation
of the thermostat [Figure 70-60-59].

Thermostat valve 0,3 mm (0.01 in)

Opening temperature @ 82° (180°F)
Thermostat valve 8 mm (0.32 in)
Full Open @ 97°C (207°F)

884 of 1052 70-60-18 T870 Service Manual

LUBRICATION SYSTEM

Description

The oil pump delivers oil from the oil pan through the oil cooler and filter, to the main oil passage in the cylinder block.
From the cylinder block, oil is delivered to the piston cooling jets, crankshaft main bearings, connecting rod bearings,
camshaft bearings, rocker arms and turbo charger. Oil also is delivered to the idler gear located at the front of the engine.

Figure 70-70-1

P114327A

1. Oil Pump 8. Idler Gear

2. Relief Valve 9. Piston

3. Bypass Valve 10. Crankshaft Main Bearing

4. Oil Cooler 11. Connecting Rod Bearing

5. Oil Filter 12. Camshaft Bearing

6. Bypass Valve 13. Rocker Arm

7. Piston Cooling Jet 14. Turbo Charger

885 of 1052 70-70-1 T870 Service Manual

LUBRICATION SYSTEM (CONT’D) Figure 70-70-4

Oil Pan Removal And Installation

1
Remove the engine / hydrostatic pump package from the
loader. (See Engine Removal And Installation on Page
70-10-15.)

Drain the engine oil. (See Removing And Replacing Oil

And Filter on Page 10-110-2.)

Figure 70-70-2 2

P115953

Install the oil pan (Item 2) [Figure 70-70-4].

NOTE: Assemble the adhesive-applied parts within

ten minutes.
2
Tighten the bolts (Item 1) [Figure 70-70-4] from inside
toward outside and clockwise to the specified torque.

P115953 Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.

Remove the oil pan mounting bolts (Item 1) and the oil
pan (Item 2) [Figure 70-70-2].

Unscrew the bolts (Item 1) [Figure 70-70-2] from outside

toward inside and counterclockwise.

Figure 70-70-3

P121045

Apply Loctite® 5902 to the assembly surface of the oil

pan [Figure 70-70-3].

Confirm that the liquid gasket coating surface is free of

water, dust and oil in order to maintain sealing effect.

886 of 1052 70-70-2 T870 Service Manual

LUBRICATION SYSTEM (CONT’D)

Oil Pump Removal And Installation

Remove the flywheel housing cover. (See Housing

Removal And Installation on Page 70-140-2.)

Figure 70-70-5

P121044

Remove the four bolts (Item 1) and the oil pump (Item 2)
[Figure 70-70-5].

Installation: Align the oil pump O-rings with the engine

oil inlet and outlet. Torque the bolts to 22 N•m (16 ft-lb).

Figure 70-70-6

1
1

P112948A

Remove the O-rings (Item 1) [Figure 70-70-6].

NOTE: The oil pump is not serviceable. When

installing the oil pump, inspect the pump gear
for correct backlash. (See Gear Backlash on
Page 70-120-1.)

887 of 1052 70-70-3 T870 Service Manual

LUBRICATION SYSTEM (CONT’D) Oil Suction Pipe Removal And Installation

Oil Pump Relief Valve Description Remove the oil pan. (See Oil Pan Removal And
Installation on Page 70-70-2.)
The oil pump relief valve is set to 496 kPa (4,9 bar) (72
psi). Figure 70-70-7

2
3
4

P115964

Remove the mounting bolts (Item 1) [Figure 70-70-7].

Remove the oil delivery tube (Item 2), oil suction tube
(Item 3) and the O-rings (Item 4) [Figure 70-70-7].

Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.

888 of 1052 70-70-4 T870 Service Manual

LUBRICATION SYSTEM (CONT’D) Oil Filter Head Removal And Installation

Oil Cooler Removal And Installation Remove the oil cooler. (See Oil Cooler Removal And
Installation on Page 70-70-5.)
Drain the engine oil. (See Removing And Replacing Oil
And Filter on Page 10-110-2.) Figure 70-70-10

Drain the coolant. (See Removing And Replacing

Coolant on Page 10-90-5.)

Figure 70-70-8
1
1

1 1

P121057A

1 1 Remove the mounting bolts (Item 1) [Figure 70-70-10]

and the filter head.
P121057
Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.

Remove the mounting bolts (Item 1) [Figure 70-70-8]. Figure 70-70-11

Remove the cooler from the filter head.

Figure 70-70-9
1

1
1
1
P112893A

Remove the O-rings (Item 1) [Figure 70-70-11].

P121057A

Remove the O-rings (Item 1) [Figure 70-70-9].

889 of 1052 70-70-5 T870 Service Manual

LUBRICATION SYSTEM (CONT’D)

Oil Cooler Bypass Description

The oil cooler bypass is set to 145 kPa (1,4 bar) (21 psi).

890 of 1052 70-70-6 T870 Service Manual

FUEL SYSTEM

Description

Figure 70-80-1

8 7

3
2
9

NA9882

The fuel is drawn from the fuel tank (Item 1) to the fuel filter (Item 2). From the filter, fuel is drawn to the transfer pump /
high pressure pump (Item 3). Fuel at as high of a pressure as 180000 kPa (1800 bar) (26,000 psi) is delivered from the
fuel pump to the common rail (Item 4). From the rail, fuel is delivered to the fuel injector (Item 5). Unused fuel from the
injector flows back to the pump (Item 3). Unused fuel from the pump will flow to the fuel bypass valve (Item 6) or the fuel
recirculation valve (earlier version) (Item 7) or (later version) (Item 8). When the fuel is colder than 27°C (81°F), the valve
will be open. When the valve is open, fuel will flow through the valve and back to the inlet side of the fuel filter (Item 2).
When the fuel is warmer than 27°C (81°F), the valve will be closed. When the valve is closed, fuel will flow to the fuel
cooler (Item 9) [Figure 70-80-1] and back to the fuel tank.

891 of 1052 70-80-1 T870 Service Manual

FUEL SYSTEM (CONT’D) Figure 70-80-3

High Pressure Pump Removal And Installation

WARNING 2
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 3
enters skin or eyes, get immediate medical attention
P121059A
from a physician familiar with this injury.
W-2072-0807

Remove the bolt (Item 1), the dipstick and dipstick tube
NOTE: Allow 5 minutes after the engine is shut down (Item 2) [Figure 70-80-3].
for the fuel pressure to bleed down.
Disconnect the wire harness connectors (Item 3) [Figure
Remove the oil filter head. (See Oil Filter Head Removal 70-80-3].
And Installation on Page 70-70-5.)
Installation: Replace the O-ring on the dipstick tube and
Remove the intake air heater. (See Intake Air Heater tighten the bolt to 9,8 N•m (7.2 ft-lb) torque.
Removal And Installation on Page 70-90-1.)
Figure 70-80-4
Remove the intake stake. (See Intake Air Heater Tube
Removal And Installation on Page 70-90-2.)
2
Figure 70-80-2
1

3
1

P121064

1 Remove the two fuel return lines (Item 1) [Figure 70-80-

P115923A 4].

Remove the bolt (Item 2) and the fuel injection line (Item
Remove the fuel inlet line (Item 1) and the fuel return line 3) [Figure 70-80-4].
(Item 2) [Figure 70-80-2] from the high pressure pump.
Install caps and plugs. Installation: Tighten the bolt to 22 N•m (16 ft-lb) torque.

Installation: Tighten the fuel injection nuts to 29,4 N•m

(21.7 ft-lb) torque.

NOTE: Both the high pressure fuel lines and return

fuel line are a one time use line. Replace the
fuel lines with new fuel lines after removal.

892 of 1052 70-80-2 T870 Service Manual

FUEL SYSTEM (CONT’D) NOTE: It does not matter what stroke you are on since
the pump turns 1:1 with the crankshaft.
High Pressure Pump Removal And Installation
(Cont’d) Figure 70-80-7

Figure 70-80-5

1 1

2 2
P127705

1
P115955
Rotate the gear until the two dots (Item 1) on the drive
gear are as close to centered with the drill hole (Item 2)
Remove the three nuts (Item 1) and the high pressure [Figure 70-80-7] in the pump housing.
pump (Item 2) [Figure 70-80-5].
Figure 70-80-8
Installation: Tighten the nuts to 22 N•m (16 ft-lb) torque.

When replacing the high pressure pump, the pump timing 1

needs to be as close as possible. If the gearcase cover is
removed (See Gear Timing on Page 70-120-2.) for the
correct procedure. If installing the high pressure pump 3
without removing the gearcase cover, follow [Figure 70-
80-6] through [Figure 70-80-8] for the correct procedure
2
Figure 70-80-6
3

P127706

1 2
Install the high pressure pump in the gearcase. The gear
(Item 1) will turn slightly as it engages the idler gear. The
timing mark (Item 2) on the idler gear will be aligned with
the timing marks (Item 3) [Figure 70-80-8] on the pump
gear.

NOTE: The gearcase cover is removed for photo

P127704 clarity.

Installation: If equipped with a fuel recirculation valve,

Rotate the crankshaft until cylinders 1 and 4 are at top use the procedure on page 70-80-12 to remove air from
dead center. The mark (Item 1) on the gearcase cover the fuel system.
will be aligned with the mark (Item 2) [Figure 70-80-6] on
the crankshaft pulley.

893 of 1052 70-80-3 T870 Service Manual

FUEL SYSTEM (CONT’D) Fuel Cooler Removal And Installation

High Pressure Pump Drive Gear Removal And Remove the rear grille from the loader. (See Removing
Installation on Page 50-60-1.)

Figure 70-80-9 Figure 70-80-11

3
2
3
2

1
1

P115956 P121216A

Remove the nut (Item 1) and the drive gear (Item 2) from Remove the fuel lines (Item 1), bolt (Item 2) and the fuel
the high pressure pump drive gear (Item 3) [Figure 70- cooler (Item 3) [Figure 70-80-11].
80-9].
Installation: If equipped with a fuel recirculation valve,
Installation: Tighten the nut to 58,8 - 68,6 N•m (43.4 - use the procedure on page 70-80-12 to remove air from
50.6 ft-lb) torque. the fuel system.

Fuel Temperature Sensor Removal And Installation

Figure 70-80-10

P127639

Remove the electrical connector (Item 1) and the fuel

temperature sensor (Item 2) [Figure 70-80-10].

Installation: Tighten the fuel temperature sensor to 8,8 -

11,8 N•m (78 - 104 in-lb) torque.

894 of 1052 70-80-4 T870 Service Manual

FUEL SYSTEM (CONT’D)

Fuel Cooler Bypass Valve Removal And Installation

Figure 70-80-12

1 1

P121124

Remove the clamps (Item 1) [Figure 70-80-12] and fuel

lines.

Remove the bolt (Item 2) [Figure 70-80-12].

Remove the bypass valve (if equipped).

Installation: Install the bypass valve according to the

flow arrow printed on the valve.

895 of 1052 70-80-5 T870 Service Manual

FUEL SYSTEM (CONT’D) Later Version

Fuel Recirculation Valve Removal And Installation Figure 70-80-15

Earlier Version

Figure 70-80-13
2

P121903
1

Remove the bolts (Item 1) and reposition the fuel filter

P121903 (Item 2) [Figure 70-80-15].

Figure 70-80-16
Remove the bolts (Item 1) and reposition the fuel filter
(Item 2) [Figure 70-80-13].
1
2
Figure 70-80-14

2
2 4

4
2
3
3 1 P121605

Pull out the FRV bracket (Item 1) and remove the clamps
P121638 and fuel lines (Item 2). Remove the fuel connector (Item
3) and the tie strap (Item 4) [Figure 70-80-16].

Pull out the FRV bracket (Item 1) and remove the clamps Remove the fuel recirculation valve.
and fuel lines (Item 2). Remove the fuel connector (Item
3) and the bolts and nuts (Item 4) [Figure 70-80-14]. Installation: Use the procedure on page 70-80-12 to
remove air from the fuel system.
Remove the fuel recirculation valve.

Installation: Use the procedure on page 70-80-12 to

remove air from the fuel system.

896 of 1052 70-80-6 T870 Service Manual

FUEL SYSTEM (CONT’D) Figure 70-80-18

Fuel Rail Assembly Removal And Installation

WARNING 2
4 1
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
P121066
from a physician familiar with this injury.
W-2072-0807

Remove the fuel return line (Item 1) and disconnect the

NOTE: Allow engine to cool completely. fuel rail pressure sensor (Item 2) [Figure 70-80-18].

Remove the SCR. (See SCR Removal And Installation Remove the bolt (Item 3) and the fuel injection line (Item
on Page 70-30-8.). 4) [Figure 70-80-18].

Remove the intake air heater. (See Intake Air Heater Installation: Tighten the bolt to 22 N•m (16 ft-lb) torque.
Removal And Installation on Page 70-90-1.)
Installation: Tighten the fuel injection nuts to 29,4 N•m
Remove the intake stake. (See Intake Air Heater Tube (21.7 ft-lb) torque.
Removal And Installation on Page 70-90-2.)
Figure 70-80-19
Figure 70-80-17

1
1 1 1
1
1

P121067
P121065

Remove the fuel rail assembly mounting bolts (Item 1)

Remove the injection lines (Item 1) [Figure 70-80-17]. and the fuel rail assembly (Item 2) [Figure 70-80-19].

Installation: Tighten the fuel injection nuts to 29,4 N•m Installation: Tighten the bolt to 22 N•m (16 ft-lb) torque.
(21.7 ft-lb) torque.
NOTE: Take care not to damage the fuel rail during
NOTE: Both the high pressure fuel lines and return removal and installation.
fuel line are a one time use line. Replace the
fuel lines with new fuel lines after removal. Installation: If equipped with a fuel recirculation valve,
use the procedure on page 70-80-12 to remove air from
the fuel system.

897 of 1052 70-80-7 T870 Service Manual

FUEL SYSTEM (CONT'D) Figure 70-80-21

Fuel Injector Removal And Installation

3 2

WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or 1
1
death. Fluid leaks under pressure may not be visible. 1
Use a piece of cardboard or wood to find leaks. Do 1
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
P115882
from a physician familiar with this injury.
W-2072-0807

Remove the fuel injection lines (Item 1) [Figure 70-80-

NOTE: Allow engine to cool completely. 21].

Remove the SCR. (See SCR Removal And Installation Remove the injector wire harness (Item 2) and return fuel
on Page 70-30-8.). line (Item 3) [Figure 70-80-21].

Figure 70-80-20 Installation: Tighten the fuel injection nuts to 29,4 N•m
(21.7 ft-lb) torque.
2
1 NOTE: Both the high pressure fuel lines and return
fuel line are a one time use line. Replace the
fuel lines with new fuel lines after removal.

Figure 70-80-22

1
2

1 P114430

Push the lock tabs (Item 1) in to release the hose (Item 2)

from the valve cover fitting (Item 3) [Figure 70-80-20]
and remove the hose.

P115959

Remove the bolts (Item 1) and the valve cover (Item 2)

[Figure 70-80-22].

Installation: Tighten the bolts to 7,8 N•m (5.8 ft-lb)

torque.

898 of 1052 70-80-8 T870 Service Manual

FUEL SYSTEM (CONT'D) Figure 70-80-25

Fuel Injector Removal And Installation (Cont’d)

Figure 70-80-23
1

1
P112930A

Remove the injector (Item 1) [Figure 70-80-25].

P112928
NOTE: Do not get the injectors out of order. If the
injectors get out of order, it is necessary to
Remove the seal (Item 1) [Figure 70-80-23] from the perform injector coding. (See Injector Coding
cover. on Page 70-80-10.)

Figure 70-80-24 When replacing injectors, it is necessary to

perform injector coding. (See Injector Coding
on Page 70-80-10.)

Figure 70-80-26
1

2
1
P112929A
2

Remove the bolt (Item 1) and the injector retainer (Item 2)

[Figure 70-80-24].
P121444

Installation: Tighten the bolt to 39,2 - 46,1 N•m (29 - 40

ft-lb) torque. Remove the sealing washer (Item 1) from the bottom of
the injector (Item 2) [Figure 70-80-26].

NOTE: The sealing washers must be replaced with

new sealing washers when installing the
injectors.

Installation: If equipped with a fuel recirculation valve,

use the procedure on page 70-80-12 to remove air from
the fuel system.

899 of 1052 70-80-9 T870 Service Manual

FUEL SYSTEM (CONT’D) Figure 70-80-29

Injector Coding

NOTE: When replacing any of the injectors the ID 2

code must be written to the ECU using the
Bobcat Engine Analyzer Diagnostic Tool.
1
Each injector has there own Identification code to inform
the ECU of the injectors performance (compensating for
slight mechanical differences).

Connect the Bobcat Engine Analyzer Diagnostic Tool.

Figure 70-80-27
P127161

The injector ID code (Item 1) is written on the top of the

injector (Item 2) [Figure 70-80-29].
2
Figure 70-80-30

1
1

P127162

From the menu, click “Part Replacement” button (Item 1),

then click C3I Injector Coding “Apply” button (Item 2) 2
[Figure 70-80-27].

Figure 70-80-28 P127160

Write the ID code(s) (Item 1) [Figure 70-80-30] to the

correct cylinder box for the injector.

NOTE: There are no letters i or o in the injector code,

the numbers 1 and 0 are used for the code.

Click on “Write” button (Item 2) [Figure 70-80-30] to save

the code(s) to the ECU.

P127160

The current injector codes that are stored in the ECU will
be displayed [Figure 70-80-28].

900 of 1052 70-80-10 T870 Service Manual

FUEL SYSTEM (CONT’D)

Injector Coding (Cont’d)

Figure 70-80-31

2
1

P127162

From the menu, click “Part Replacement” button (Item 1),

then click Injector “Apply” button (Item 2) [Figure 70-80-
31].

Start the engine and let the machine run at full throttle for
ten minutes to allow ECU learning.

901 of 1052 70-80-11 T870 Service Manual

FUEL SYSTEM (CONT’D)

Removing Air From The Fuel System WARNING

After removing or replacing fuel system components
(high pressure pump, fuel rail, injectors or fuel cooler) the AVOID INJURY OR DEATH
following procedure must be used to remove air from the Always clean up spilled fuel or oil. Keep heat, flames,
fuel system if equipped with a fuel recirculation valve. sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
NOTE: The same procedure can be used for either explosion or fire.
the earlier or later fuel recirculation valve. W-2103-0508

Figure 70-80-33

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 1
from a physician familiar with this injury.
W-2072-0807

Figure 70-80-32

2
NA11009SA

P121904 Pinch off the indicated fuel hose (Item 1) [Figure 70-80-
33] using a locking hose pinching plier or similar tool.
Open the air vent plug (Item 1) [Figure 70-80-32] on the
Squeeze the hand pump (primer bulb) (Item 2) [Figure
fuel filter assembly three full turns.
70-80-33] twenty times or until the primer bulb is difficult
to squeeze.
Squeeze the hand pump (priming bulb) (Item 2) [Figure
70-80-32] until fuel flows from the air vent plug with no air
Start the machine and let machine idle for two minutes.
bubbles.
Shut the machine off and remove the pinching plier from
Close the air vent plug (Item 1) [Figure 70-80-32].
the fuel hose (Item 1) [Figure 70-80-33].

902 of 1052 70-80-12 T870 Service Manual

FUEL SYSTEM (CONT’D)

Removing Air From The Fuel System (Cont’d)

Figure 70-80-34

P121904

Open the air vent plug (Item 1) [Figure 70-80-34] on the

fuel filter assembly three full turns.

Squeeze the hand pump (priming bulb) (Item 2) [Figure

70-80-34] until fuel flows from the air vent plug with no air
bubbles.

Close the air vent plug (Item 1) [Figure 70-80-34].

903 of 1052 70-80-13 T870 Service Manual

904 of 1052 70-80-14 T870 Service Manual
CYLINDER HEAD Figure 70-90-3

Intake Air Heater Removal And Installation 1

5
2
Figure 70-90-1

3
P115996
2

Remove the bolt (Item 1) and the boost pressure sensor

P115922 (Item 2), [Figure 70-90-3].

Remove the four retaining bolts (Item 3) and the air

Disconnect the two wires (Item 1), remove the wire mount heater (Item 4) and gasket (Item 5) [Figure 70-90-3].
bolt (Item 2) and reposition the air heater wire (Item 3)
[Figure 70-90-1]. Installation: Tighten the retaining bolts to 22 N•m (16 ft-
lb) torque.
Figure 70-90-2
Installation: Tighten the boost pressure sensor bolt to
2 9,8 N•m (7.2 ft-lb) torque.

P121056

Disconnect the boost pressure sensor connector (Item 1)

and remove the clamp / hose (Item 2) [Figure 70-90-2].

905 of 1052 70-90-1 T870 Service Manual

CYLINDER HEAD (CONT’D)

Intake Air Heater Tube Removal And Installation

Remove the intake air heater. (See Intake Air Heater

Removal And Installation on Page 70-90-1.)

Figure 70-90-4

6 5

3
3 2
4
1 P115997

Remove the EGR pipe bolts (Item 1) and the EGR pipe
(Item 2) and gaskets (Item 3) [Figure 70-90-4].

Remove the retaining bolts (Item 4) and the intake air

heater tube (Item 5) and gasket (Item 6) [Figure 70-90-
4].

Installation: Tighten the retaining and EGR bolts to 22

N•m (16 ft-lb) torque.

906 of 1052 70-90-2 T870 Service Manual

CYLINDER HEAD (CONT’D) Figure 70-90-7

Valve Clearance Adjustment 2

NOTE: Valve clearance must be inspected and

adjusted when engine is cold.

Remove the SCR. (See SCR Removal And Installation

on Page 70-30-8.).
1 1 1
Remove the DOC. (See Removal And Installation on
Page 70-40-1.)

Figure 70-90-5

2 P115881
1

Remove the three wire harness holders (Item 1) from the

valve cover (Item 2) [Figure 70-90-7].

Figure 70-90-8
3

2 1

1 P114430

Push the lock tabs (Item 1) in to release the hose (Item 2)

from the valve cover fitting (Item 3) [Figure 70-90-5] and
remove the hose. 2

Figure 70-90-6 1
P115882

2 2 2
2
Remove the bolts (Item 1) and the valve covers (Item 2)
[Figure 70-90-8] from the engine.

Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.

1 1 1
1

P115880

Remove the four heat shield bolts (Item 1) and the

mounting brackets (Item 2) [Figure 70-90-6].

907 of 1052 70-90-3 T870 Service Manual

CYLINDER HEAD (CONT’D) Figure 70-90-11

Valve Clearance Adjustment (Cont’d) 2

Figure 70-90-9

1 1

2
P114410A

Loosen the nut (Item 1) and adjust the screw (Item

P114409A 2) [Figure 70-90-11] to obtain the correct clearance.

Installation: Tighten the nut to 15 N•m (11 ft-lb) torque.

Measure the valve clearance between the rocker arm
(Item 1) and the valve bridge head (Item 2) [Figure 70-
90-9].

The intake valve clearance is 0,4 mm and the exhaust

valve clearance is 0,45 mm.

Figure 70-90-10

Cylinder
#1 #2 #3 #4
Number
Exhaust

Exhaust

Exhaust

Exhaust
Intake

Intake

Intake

Intake

Rotation
Angle

TDC (#1
Cylinder) • • • •
360°
Rotation • • • •

To adjust the valve clearance reference the chart [Figure

70-90-10].

With the #1 cylinder set at compression top dead center

set the valves on #1 cylinder intake and exhaust. #2
cylinder intake valve and #3 cylinder exhaust valve.

Rotate engine 360° to make #4 cylinder at top dead

center. Adjust the #2 cylinder exhaust valve, #3 cylinder
intake valve and #4 cylinder intake and exhaust valve.

908 of 1052 70-90-4 T870 Service Manual

CYLINDER HEAD (CONT’D) Figure 70-90-13

Cylinder Head Removal And Installation

1 3 1
1
Remove the engine. (See Engine Removal And
Installation on Page 70-10-15.)

Remove the alternator. (See Removal And Installation on

Page 60-30-5.)

Remove the fuel injectors. (See Fuel Injector Removal 2

1 1
And Installation on Page 70-80-8.) 1

Remove the intake stake. (See Intake Air Heater Tube

Removal And Installation on Page 70-90-2.)
P121106
Remove the oil filter head. (See Intake Air Heater Tube
Removal And Installation on Page 70-90-2.)
Remove the bolts (Item 1) and the intake manifold (Item
Remove the fuel rail assembly. (See Fuel Rail Assembly 2) [Figure 70-90-13].
Removal And Installation on Page 70-80-7.)
Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.
Remove the EGR. (See Removal And Installation on
Page 70-150-2.) Remove the intake temperature sensor (Item 3) [Figure
70-90-13].
Remove the thermostat housing. (See Thermostat
Housing Removal And Installation on Page 70-60-17.) Installation: Tighten the sensor to 29,4 N•m (21.7 ft-lb)
torque.
Figure 70-90-12
Figure 70-90-14
1
3 1

1 2 1
3 2

P121105
P115971

Remove the bolts (Item 1) and the exhaust manifold (Item

2) [Figure 70-90-12]. Remove the bolts (Item 1) [Figure 70-90-14].

Installation: Tighten the bolts to 30,4 N•m (22.4 ft-lb) Installation: Tighten the bolts to 9,8 N•m (7.2 ft-lb)
torque. torque.

Remove the turbo exhaust gas temperature sensor (Item Loosen the bolts (Item 2) and remove the heat shield
3) [Figure 70-90-12]. (Item 3) [Figure 70-90-14].

Installation: Tighten the sensor to 44,1 N•m (32.5 ft-lb)

torque.

909 of 1052 70-90-5 T870 Service Manual

CYLINDER HEAD (CONT’D) Figure 70-90-17

Cylinder Head Removal And Installation (Cont’d)

1
Figure 70-90-15

2
1

3 P114447A

Remove the seal (Item 1) [Figure 70-90-17] from the

P115973 cover.

Figure 70-90-18
Remove the bolts (Item 1) and the gasket (Item 2)
[Figure 70-90-15].

The mark of TOP (Item 3) [Figure 70-90-15] should be 2 1

facing upward when installed.

Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.

Figure 70-90-16

1 P112935

Remove the bolts (Item 1) and the rocker arm assembly

(Item 2) [Figure 70-90-18].

Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.

Be sure to adjust the valve clearance. (See Valve

P115988 Clearance Adjustment on Page 70-90-3.)

Loosen the bolts (Item 1) and remove the valve cover

(Item 2) [Figure 70-90-16].

Installation: Tighten the bolts to 7 - 8 N•m (5 - 6 ft-lb)

torque.

910 of 1052 70-90-6 T870 Service Manual

CYLINDER HEAD (CONT’D) Figure 70-90-21

Cylinder Head Removal And Installation (Cont’d)

Figure 70-90-19

4
12 5 13
1 16 8 1
9 17

15 7 2 10 18
11 3 6 14

2
P114455

Installation: Tighten the head bolts in the sequence

P112936 shown [Figure 70-90-21].

Initial torque 44 N•m (33 ft-lb).

Remove the push rods (Item 1) and valve spring bridges
(Item 2) [Figure 70-90-19]. 2nd torque 90°.

Figure 70-90-20 3rd torque 90°.

NOTE: Before installing the cylinder head, piston

step height must be measured to determine
2 the correct head gasket thickness required.
1

Figure 70-90-22

P112937

Remove the head bolts (Item 1), cylinder head (Item 2)

[Figure 70-90-20] and gasket.
1
P114045

Rotate the crankshaft until the piston is at top dead

center. Measure the piston step height in the areas
shown (Item 1) [Figure 70-90-22].

Repeat the procedure for all four pistons.

911 of 1052 70-90-7 T870 Service Manual

CYLINDER HEAD (CONT’D) Cylinder Head Disassembly And Assembly

Cylinder Head Removal And Installation (Cont’d) Figure 70-90-24

Figure 70-90-23

4
3
2
1

P114035

P114448
Compress the valve spring and remove the retainers
(Item 1). Release the valve spring compression tool.
Select the correct class head gasket. The class of gasket Remove the spring seat (Item 2), spring (Item 3) and
is stamped in the gasket where shown (Item 1) [Figure valve stem seals (Item 4) [Figure 70-90-24].
70-90-23].
Figure 70-90-25
Gasket Class and Average Piston Step
Thickness Height
Class A 0,9 mm 0,24 - 0,33 mm
(0.0354 in) (0.0095 - 0.0130in)
Class B 1,0 mm 0,33 - 0,43 mm
(0.0394 in) (0.0130 - 0.0169 in)
Class C 1,1 mm 0,43 - 0,52 mm
(0.0433 in) (0.0169 - 0.0205 in)

P114036

Remove the valves (Item 1) [Figure 70-90-25] from the

block.

912 of 1052 70-90-8 T870 Service Manual

CYLINDER HEAD (CONT’D) Figure 70-90-27

Cylinder Head Inspection

Remove the valve and spring from the cylinder head.

(See Cylinder Head Disassembly And Assembly on Page
70-90-8.)

Thoroughly clean the cylinder head surface.

Figure 70-90-26

1 P115981

Put the straight edge on the cylinder head’s four sides

and two diagonal as shown in figure [Figure 70-90-27].
2
The maximum distortion of the head surface is ± 0,05
mm in 100 mm (± 0.002 inches in 4.0 inches), If the
measurement exceeds the specification, replace the
cylinder head.
P115982
Repeat the procedure on the intake and exhaust surface
of the head.
Put a straight edge (Item 1) [Figure 70-90-26] on the
cylinder head.

NOTE: Do not put the straight edge across

combustion chambers.

Put a feeler gauge (Item 2) [Figure 70-90-26] between

the straight edge and the surface of the cylinder head.

913 of 1052 70-90-9 T870 Service Manual

CYLINDER HEAD (CONT’D) Figure 70-90-29

Cylinder Head Top Clearance

Thoroughly clean the cylinder head surface.

Figure 70-90-28

1
1

P-85173

1
Remove the solder and measure it [Figure 70-90-29].
1
Top Clearance
1,69 - 2,52 mm
Intake Valve
(0.0665 - 0.0992 in)
1,54 - 2,33 mm
Place four pieces of 3 mm (0.118 in) solder on the piston Exhaust Valve
(0.0606 - 0.0917 in)
where shown (Item 1) [Figure 70-90-28].

Turn the piston to B.D.C.

Install the cylinder head and bolts. Torque the bolts in the
correct sequence.

Rotate the crankshaft.

914 of 1052 70-90-10 T870 Service Manual

CYLINDER HEAD (CONT'D) Valve Stem Height

Valve Step Height Figure 70-90-31

Figure 70-90-30

P115984

P115985
Measure the valve stem height from the valve to the
cylinder head as shown [Figure 70-90-31].
Measure the valve at four points as shown [Figure 70-
90-30]. Valve Stem Height
20,8 - 21,3 mm
Valve Step Height Intake Valve
(0.8189 - 0.8386 in)
0,6 - 0,9 mm 20,8 - 21,3 mm
Intake Valve Exhaust Valve
(0.0236 - 0.0354 in) (0.8189 - 0.8386 in)
0,6 - 0,9 mm
Exhaust Valve
(0.0236 - 0.0354 in)

915 of 1052 70-90-11 T870 Service Manual

CYLINDER HEAD (CONT’D) Valve

Valve Guide Figure 70-90-33

Figure 70-90-32

P114056

P114042
Measure the overall length of the valve [Figure 70-90-
33].
Measure the valve guide (Item 1) [Figure 70-90-32]
inside diameter at three different depths. Valve Length
Intake Valve 108,3 mm (4.2638 in)
7,0 - 7,015 mm
Valve Guide ID Exhaust Valve 110,3 mm (4.3425 in)
(0.2756 - 0.2762 in)
Measure the outside diameter of the valve stem [Figure
Measure the valve guide length.
70-90-33].
43,4 - 43,6 mm
Valve Guide Length 6,97 ± 0,007 mm
(1,7087 - 1,7165 in) Valve Stem O.D.
(0.2744 ± 0.0003 in)

916 of 1052 70-90-12 T870 Service Manual

CYLINDER HEAD (CONT’D)

Valve Spring

Figure 70-90-34

B-3680

Measure the length of the valve spring. If the

measurement is less than the allowable limit, replace the
spring [Figure 70-90-34].

Free Length 55.23 mm (2.1744 in)

Put the spring on a flat surface, place a square on the

side of the spring [Figure 70-90-34].

Rotate the spring and measure the maximum tilt. If the

measurement exceeds the allowable limit, replace the
spring.

Tilt Allowable Limit 1,8 mm (0.0708 in)

917 of 1052 70-90-13 T870 Service Manual

CYLINDER HEAD (CONT'D) Figure 70-90-37

Rocker Arm Shaft Disassembly And Assembly

Figure 70-90-35

1 1

P114011

2
Remove the mount (Item 1) [Figure 70-90-37]. Continue
P114009 to remove the rocker arms, springs and mounts.

Figure 70-90-38
Remove the bolt (Item 1) and mount (Item 2) [Figure 70-
90-35].

Figure 70-90-36

P114012
1

Remove the bolt (Item 1) [Figure 70-90-38] and the

P114010 mount from the shaft.

Remove the rocker arm (Item 1), spring (Item 2) and

rocker arm (Item 3) [Figure 70-90-36].

918 of 1052 70-90-14 T870 Service Manual

CYLINDER HEAD (CONT'D) Push Rod Inspection

Rocker Arm Shaft Inspection Figure 70-90-41

Figure 70-90-39

1
1 P-76926

P114054
Place the push rod on V blocks and measure the
alignment [Figure 70-90-41].
Inspect the wear points (Item 1) [Figure 70-90-39] for
wear and damage. Push Rod Alignment 0,5 mm (0.0207 in)
Measure the ID of the rocker arms (Item 2) [Figure 70-
90-39].

Rocker Arm ID 16,03 mm (0.6311 in)

Figure 70-90-40

P114055

Inspect the shaft (Item 1) [Figure 70-90-40] for wear and

damage.

Measure the OD of the shaft.

Rocker Arm Shaft OD 16,15 mm (0.6358 in)

919 of 1052 70-90-15 T870 Service Manual

920 of 1052 70-90-16 T870 Service Manual
CRANKSHAFT AND PISTONS Figure 70-100-2

Piston And Connecting Rod Removal And

Installation

Remove the cylinder head. (See Cylinder Head Removal

And Installation on Page 70-90-5.) 1
Remove the top edge from the cylinder bore with a ridge 2
reamer.

Remove the oil pan and oil pump strainer. (See Oil Pan
Removal And Installation on Page 70-70-2.)

Figure 70-100-1
P112954

Remove the cap (Item 1) and bearing (Item 2) [Figure

70-100-2].

1 Figure 70-100-3

P112953

Remove the connecting rod bolts (Item 1) [Figure 70-

100-3].

Installation: Tighten the bolts to an initial torque of 29,4

N•m (21.7 ft-lb). Tighten the bolts an additional 90°. P112955

NOTE: The rod bolts are a one time use bolt. Use new
bolts when installing the connecting rods. Remove the piston / connecting rod (Item 1) [Figure 70-
100-3] from the cylinder block.

NOTE: Install the piston / connecting rod assembly in

to the bore it was removed from.

Repeat the procedure to remove the remaining piston /

connecting rod assemblies.

921 of 1052 70-100-1 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 70-100-6

Piston And Connecting Rod Inspection

Figure 70-100-4
1

2
2

P114005

1 Remove the connecting rod (Item 1) [Figure 70-100-6]

P114003 from the piston.

Installation: The mark (Item 2) on the piston and

Remove the bearings (Item 1) [Figure 70-100-4] from the connecting rod must be on the same side. When
rod and cap. installing the piston in the cylinder block, the marks (Item
2) [Figure 70-100-6] go the flywheel side of the engine.
NOTE: The yellow code 1,497 - 1,502 mm (0.0589 -
0.0591 in) bearing is the only service bearing Figure 70-100-7
available.
1
The rod and cap are a fracture design. The cap can only
fit the rod in one direction and is not interchangeable with
other rods.

Figure 70-100-5

1 1 1
P114007

Remove the rings (Item 1) [Figure 70-100-7].

P114004

Remove the snap ring (Item 1) and wrist pin (Item 2)

[Figure 70-100-5].

922 of 1052 70-100-2 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 70-100-10

Piston And Connecting Rod Inspection (Cont’d)

Figure 70-100-8

1
P114052

Remove the carbon from the ring grooves. Measure the

P114008 clearance between the ring and groove with a feeler
gauge [Figure 70-100-10].

Installation: Install the rings with the R (Item 1) [Figure Top Ring 0,083 - 0,137 mm
70-100-8] towards the top of the piston. Install the rings (0.0033 - 0.0054 in)
with the ring gap 120° apart. 0,070 - 0,110 mm
Second Ring
(0.0028 - 0.0043 in)
Figure 70-100-9
Oil Ring 0,03 - 0,07 mm
(0.0012 - 0.0028 in)

P114053

Install a piston ring into the lower part of the cylinder

bore. Measure the ring gap with a feeler gauge [Figure
70-100-9].

Top Ring Gap 0,2 - 0,4 mm

(0.0079 - 0.0157 in)
Second Ring End Gap 0,55 - 0,70 mm
(0.0217 - 0.0276 in)
Oil Ring End Gap 0,2 - 0,4 mm
(0.0079 - 0.0157 in)

923 of 1052 70-100-3 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 70-100-13

Timing Wheel Removal And Installation

Figure 70-100-11

2 1

P121018

Remove the bolts (Item 1) and the front oil seal holder
P121016 (Item 2) [Figure 70-100-13].

Installation: Apply Loctite® 5902 to the assembly

Remove the bolt (Item 1) and crankshaft pulley (Item 2) surface of the front seal holder.
[Figure 70-100-11].
Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.
Installation: Apply Loctite® 587 to the crankshaft pulley
bolt. Figure 70-100-14

Installation: Tighten the bolt to 255 N•m (188 ft-lb)

torque.
1
Figure 70-100-12

2
3
2

P121019

Use front seal installer (7031369) (Item 1), to install a

new front oil seal (Item 2) into the front oil seal holder
P121017 (Item 3) [Figure 70-100-14].

Remove the front oil seal (Item 1) from the front oil seal
holder (Item 2) [Figure 70-100-12].

924 of 1052 70-100-4 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT’D)

Timing Wheel Removal And Installation (Cont’d)

Figure 70-100-15

P121023

Remove the bolt (Item 1) and the crank position sensor

(Item 2) [Figure 70-100-15].

Figure 70-100-16

2
P121024

Remove the key (Item 1) and the timing wheel (Item 2)

[Figure 70-100-16].

925 of 1052 70-100-5 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 70-100-19

Crankshaft Removal And Installation

Figure 70-100-17

1
2 1

P112957A

1
Remove the crankcase (Item 1) [Figure 70-100-19].
P112956A
Installation: Apply Loctite® 5902 on the sealing edge of
the crankcase.
Remove the main bearing bolts (Item 1) and crankcase
bolts (Item 2) [Figure 70-100-17]. Figure 70-100-20

Figure 70-100-18
1

26 22 18 14 11 15 19 23

8 4 1 5 9

7 3 2 6 10

25 21 17 13 12 16 20 24
P112958A

P114438
Remove the crankshaft (Item 1) [Figure 70-100-20].

Installation: Tighten the main bearing bolts (Item 1 - 10)

[Figure 70-100-18] to an initial torque of 54 N•m (40 ft-lb)
torque in the order shown. After the initial torque, tighten
the main bearing bolts an additional 90°. Tighten the
main bearing bolts a second time by an additional 90°.

Tighten the crankcase bolts (Item 11 - 26) 22 N•m (16 ft-

lb) torque in the order shown.

926 of 1052 70-100-6 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 70-100-23

Crankshaft Removal And Installation (Cont’d)

Figure 70-100-21

1 1

P114024

Remove the bolts / check valves (Item 1) [Figure 70-100-

P114018A 23] and remove the oilers.

Installation: Tighten the bolts to 20 N•m (14 ft-lb) torque.

Remove the crankshaft bearings (Item 1) [Figure 70-
100-21]. Figure 70-100-24

Installation: Install the bearing with the grove in the

cylinder block. The non-grooved bearing is installed in the
crankcase.

Figure 70-100-22

1
2
1

P114026

Remove the bolt / check valve assembly (Item 1) from the

oiler (Item 2) [Figure 70-100-24].
1
B114019

Remove the thrust bearings (Item 1) [Figure 70-100-22].

927 of 1052 70-100-7 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 70-100-27

Cylinder Block Inspection

Figure 70-100-25

P115977

Measure the cylinder block bore [Figure 70-100-27].

P115974
Figure 70-100-28

With the bearings and crankcase installed, measure the

main journal bearings [Figure 70-100-25].

Figure 70-100-26

P-37163

Measure the bore at three different depths and at two

points 90° apart [Figure 70-100-28].
P115976A
Cylinder Block Bore 97,990 - 98,010 mm
(3.8579 - 3.8587 in)
Measure each bearing at three different points [Figure
70-100-26]. For detailed cylinder block dimensions: (See Engine
Component Class on Page 70-100-11.)
Main Journal Bearing I.D. 79 - 79,021 mm
(3.1102 - 3.1111 in)

For detailed cylinder block dimensions: (See Engine

Component Class on Page 70-100-11.)

928 of 1052 70-100-8 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT’D)

Cylinder Block Inspection (Cont’d)

Figure 70-100-29

P115979

Measure the three camshaft bushings [Figure 70-100-

29].

Figure 70-100-30

P115980A

Measure the bearings in three different locations [Figure

70-100-30].

Cylinder Block Camshaft 45 - 45.025 mm

Bore (1.7716 - 1.7726 in)

929 of 1052 70-100-9 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Connecting Rod Inspection

Crankshaft Inspection Figure 70-100-33

Figure 70-100-31

P121030

P121022

Measure the I.D. of the connecting rod small end bore.

Place the crankshaft on a set of V blocks. Set a dial Measure the O.D. of the piston pin and the I.D. of the
indicator on a main bearing journal. Spin the crankshaft piston pin bore [Figure 70-100-33].
to determine the crankshaft warpage [Figure 70-100-31].
Connecting Rod Small 36,025 - 36,038 mm
Crankshaft Warpage End Bore (1.4183 - 1.4188 in)
Number 3 Main Journal 0,05 mm (0.0020 in) Piston Pin O.D. 35,995- 36,000 mm
0,05 mm (0.0020 in) (1.4171 - 1.4173 in)
Number 2 & 4 Main Journal
Piston Pin Bore 36,008 - 36,014 mm
(1.4176 - 1.4179 in)
Figure 70-100-32

Figure 70-100-34

P121020

P121032
Measure the crankshaft main journals and rod journals
[Figure 70-100-32].
Measure the I.D. of the connecting rod large end bore
Main Journal Diameter 74,955 - 74,970 mm [Figure 70-100-34]. Measure the bore in three different
(2.9510 - 2.9516 in) locations.

Rod Journal Diameter 62,955 - 62,970 mm Connecting Rod Large 66,000 - 66,015 mm
(2.4785 - 2.4791 in) End Bore (2.5984 - 2.5990 in)

For detailed crankshaft dimensions: (See Engine For detailed connecting rod dimensions: (See Engine
Component Class on Page 70-100-11.) Component Class on Page 70-100-11.)

930 of 1052 70-100-10 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) The connecting rod bearings are available as a service
part in one class and are coded with yellow markings.
Engine Component Class
Connecting Rod Bearing 1,497 - 1,502 mm
The pistons, connecting rods, connecting rod bearings, (0.0590 - 0.0591 in)
crankshaft, crankshaft bearings and cylinder block are
available in different classes. The class is determined by Figure 70-100-37
the size of the components and is engraved or color
coded on the component.

Figure 70-100-35
1

2
1

P114051B

The crankshaft serial number (Item 1) and main journal

P114059 diameter class (Item 2) [Figure 70-100-37] is engraved
on the flywheel end of the crankshaft.

The piston is engraved with “A” or “B” (Item 1) [Figure Crankshaft Main Journal Diameter
70-100-35].
Class A 74,955 - 74,960 mm
(2.9510 - 2.9512 in)
Class A 97,920 - 97,930 mm
(3.8551 - 3.8555 in) Class B 74,960 - 74,965 mm
(2,9512 - 2.9514 in)
Class B 97,930 - 97,940 mm
(3.8555 - 3.8559 in) Class C 74,965 - 74,970 mm
(2.9514 - 2.9516 in)
Figure 70-100-36
Crankshaft Bearing Thickness / Color
Blue 1,995 - 2,000 mm
(0.0785 - 0.0787 in)
1 Yellow 2,000 - 2,005 mm
(0.0787 - 0.0789 in)
Red 2,005 - 2,010 mm
(0.0789 - 0.0791 in)

P114058

The connecting rod is engraved on the cap (Item 1)

[Figure 70-100-36]. This letter / number must be used to
order replacement rod assemblies.

931 of 1052 70-100-11 T870 Service Manual

CRANKSHAFT AND PISTONS (CONT’D)

Engine Component Class (Cont’d)

Figure 70-100-38

P114060

The cylinder block bearing bore class (Item 1) [Figure

70-100-38] is engraved on the flange of the crankcase.

Cylinder Block Main Journal Diameter

Class A 79,000 - 79,007 mm
(2.9134 - 2.9137 in)
Class B 79,007 - 79,014 mm
(2.9137 - 2.9139 in)
Class C 79,014 - 79,021 mm
(2.9139 - 2.9142 in)

When replacing crankshaft bearings, use the chart

below.

Cylinder Block Crankshaft Main Journal 

Main Journal Diameter
Diameter Class A Class B Class C
Class A Yellow Blue Blue
Bearing Bearing Bearing
Class B Yellow Yellow Blue
Bearing Bearing Bearing
Class C Red Red Yellow
Bearing Bearing Bearing

932 of 1052 70-100-12 T870 Service Manual

CAMSHAFT Figure 70-110-41

Removal And Installation

Remove the flywheel housing. (See Housing Removal 1

And Installation on Page 70-140-2.)

Remove the rocker arms and push rods. (See Rocker

Arm Shaft Disassembly And Assembly on Page 70-90-
14.)

Remove the oil pan. (See Oil Pan Removal And

Installation on Page 70-70-2.)

NOTE: Before removing the camshaft, measure the

camshaft end play. (See Inspecting on Page P114023
70-110-2.)

Figure 70-110-39 Remove the valve tappets (Item 1) [Figure 70-110-41].

Figure 70-110-42

1
1

P121000

P115979A
Remove the bolts (Item 1) [Figure 70-110-39].

Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque. Remove the cam bearings (Item 1) [Figure 70-110-42].

Figure 70-110-40 Installation: Install the cam bearings with the holes in
the bearing lined up with the oil passage in the cylinder
block.

1
P121001

Remove the camshaft (Item 1) [Figure 70-110-40].

933 of 1052 70-110-1 T870 Service Manual

CAMSHAFT (CONT’D) Figure 70-110-45

Inspecting

Figure 70-110-43

P121006

Measure the three camshaft journals. Measure each

P121007 journal in two different areas 90° apart [Figure 70-110-
45].

Measure the gap between the thrust washer and the gear Camshaft Journal 44,95 - 44,966 mm
[Figure 70-110-43]. (1.7697 - 1.7703 in)

Thrust washer to 0,1 - 0,2 mm Figure 70-110-46

gear clearance (0.0039 - 0.0079 in)

Figure 70-110-44

1 2

P121008

P121005 Place the camshaft on V Blocks. Set up a dial indicator

as shown [Figure 70-110-46].

Remove the gear (Item 1), thrust washer (Item 2), and Rotate the camshaft and record the warpage of the
key (Item 3) [Figure 70-110-44]. camshaft.

Installation: Heat the camshaft gear to 170 - 190°C (338 Camshaft warpage 0,01 mm
- 374°F) and press the gear on to the camshaft. (0.0004 in)

934 of 1052 70-110-2 T870 Service Manual

CAMSHAFT (CONT’D)

Inspecting (Cont’d)

Figure 70-110-47

P121000

With the camshaft (Item 1) [Figure 70-110-47] installed,

use a dial indicator to measure camshaft end play.

Camshaft end play 0,1 - 0,2 mm

(0.0039 - 0.0079 in)

935 of 1052 70-110-3 T870 Service Manual

936 of 1052 70-110-4 T870 Service Manual
GEARCASE Gear End Play

Gear Backlash Figure 70-120-2

Remove the flywheel housing. (See Housing Removal 2

And Installation on Page 70-140-2.)

Figure 70-120-1

3
4
1

2 1

P121037

3
Using a dial indicator, test the end play of the crankshaft
gear (Item 1), camshaft gear (Item 2) and idle gear (Item
P121035 3) [Figure 70-120-2].

Crankshaft gear end play 0,10 - 0,31 mm

Using a dial indicator, test the backlash between the fuel (0.0039 - 0.0122 in)
injection pump gear (Item 1) to idle gear (Item 2), idle
gear to crankshaft gear (Item 3), idle gear to camshaft Camshaft gear end play 0,10 - 0,20 mm
(Item 4) [Figure 70-120-1], and crankshaft gear to oil (0.0039 - 0.0079 in)
pump gear. Idle gear end play 0,10 - 0,20 mm
(0.0039 - 0.0079 in)
Idle gear to crankshaft 0,087 - 0,202 mm
gear (0.0034 - 0.008 in)
Crankshaft gear to oil 0,066 - 0,247 mm
pump gear (0.0026 - 0.0097 in)
Idle gear to camshaft gear 0,087 - 0,213 mm
(0.0034 - 0.0084 in)
Fuel injection pump gear 0,081 - 0,196 mm
to idle gear (0.0032 - 0.0077 in)

937 of 1052 70-120-1 T870 Service Manual

GEARCASE (CONT’D) Figure 70-120-5

Gear Timing
1
Remove the flywheel housing. (See Housing Removal
And Installation on Page 70-140-2.)

Figure 70-120-3

4
1

2
2 P121035B

Idle gear (Item 1) to camshaft gear (Item 2) [Figure 70-

3 120-5].

Figure 70-120-6
P121035

The fuel injection pump gear (Item 1), idle gear (Item 2),
2
crankshaft gear (Item 3), and camshaft gear (Item 4)
[Figure 70-120-3] have timing marks. Align the marks
when assembling the gears. 1

Figure 70-120-4

1
P121035C

Idle gear (Item 1) to crankshaft gear (Item 2) [Figure 70-

120-6].

P121035A

Fuel injection pump (Item 1) to idle gear (Item 2) [Figure

70-120-4].

938 of 1052 70-120-2 T870 Service Manual

GEARCASE (CONT’D) Idle Gear Inspection

Idle Gear Removal And Installation Figure 70-120-8

Figure 70-120-7

1 2
3
2 P114057

P121011
Measure the inside diameter of the idle gear (Item 1)
[Figure 70-120-8] at four different points, on either side
Remove the bolts (Item 1), idle gear shaft (Item 2) of the bearing lubrication channel.
[Figure 70-120-7] and the idle gear (Item 3).
Idle Gear I.D. 64,0 - 64,019 mm
Installation: Tighten the bolts to 43 N•m (32 ft-lb) torque. (2.5197 - 2.5204 in)

Measure the outside diameter of the idle gear shaft (Item

2) [Figure 70-120-8] at four different points on either side
of the lubrication port.

Idle Gear Shaft O.D. 59,921 - 59,940 mm

(2.3591 - 2.3598 in)

939 of 1052 70-120-3 T870 Service Manual

940 of 1052 70-120-4 T870 Service Manual
TURBOCHARGER Removal And Installation

Description Remove the SCR. (See SCR Removal And Installation

on Page 70-30-8.)
The turbocharger is located between the exhaust and
intake manifolds. It is driven by hot exhaust gases and Remove the DOC assembly. (See Removal And
supplies air at more than atmospheric pressure to the Installation on Page 70-40-1.)
intake. Lubrication for the turbocharger is supplied with
pressurized oil from the main engine oil galley. The Remove both side access covers [Figure 10-120-5 on
location of the turbo is between the engine and the Page 10-120-2.].
blower housing.
Remove the fan duct. (See Lower Fan Duct Removal And
Figure 70-130-1 Installation on Page 70-60-4.)

1 Remove the fan duct panels. (See Removal And

Installation on Page 50-190-1.)

Figure 70-130-2

2
P121062

The oil is delivered to the turbocharger through a tubeline 1

(Item 1) and returns to the engine block through a drain
line (Item 2) [Figure 70-130-1].
P121139

The turbocharger internal components are not

serviceable. Remove the nuts (Item 1) and the exhaust pipe (Item 2)
[Figure 70-130-2].

Installation: Tighten the nuts (Item 1) [Figure 70-130-2]

to 22 N•m (16 ft-lb) torque.

941 of 1052 70-130-1 T870 Service Manual

TURBOCHARGER (CONT’D) Figure 70-130-5

Removal And Installation (Cont’d)

Figure 70-130-3
1 1

1 3

2
2
P121141

Remove the bolts (Item 1), reposition the clamp (Item 2)

P115926A and remove the drain tube assembly (Item 3) [Figure 70-
130-5].

Loosen the hose clamp (Item 1) [Figure 70-130-3]. Installation: Tighten the bolts to 9,8 N•m (7.2 ft-lb)
Remove the hose and the plug turbo inlet. torque.

Remove the hoses (Item 2) [Figure 70-130-3]. Figure 70-130-6

Figure 70-130-4
1

1
2

1 P121142

P121140
Remove the three nuts (Item 1) [Figure 70-130-6].

Remove the oil tube line bolts (Item 1) and the oil tube Installation: Tighten the nuts to 22 N•m (16 ft-lb) torque.
line (Item 2) [Figure 70-130-4].
Remove the turbo and gasket.
Installation: Tighten the bolt to 19,6 N•m (14.5 ft-lb)
torque.

NOTE: The oil delivery pipe and copper washers are

single use parts and should be replaced
whenever the oil delivery pipe and copper
washers are removed.

942 of 1052 70-130-2 T870 Service Manual

TURBOCHARGER (CONT’D)

Testing

Turn the compressor wheel gently with a finger and check

for contact.

If the wheel does not turn smoothly, check the axial and
radial clearance.

If the compressor / turbine wheel and housing is

damaged, replace the turbocharger assembly.

Figure 70-130-7

P-76099

Move the compressor / turbine wheel (Item 1) [Figure

70-130-7] (up and down, right and left).

If the compressor / turbine wheel contacts the housing,

replace the turbocharger assembly.

943 of 1052 70-130-3 T870 Service Manual

944 of 1052 70-130-4 T870 Service Manual
FLYWHEEL AND HOUSING Ring Gear Removal And Installation

Flywheel Removal And Installation Figure 70-140-2

NOTE: Engine removed for photo clarity.

1
Remove the drive belt. (See Belt Replacement on Page
30-50-2.)

Remove the belt tension pulley assembly. (See Tensioner

Pulley Removal And Installation on Page 30-50-4.)

Figure 70-140-1

P114378A

1
The ring gear (Item 1) [Figure 70-140-2] on the flywheel
2 is an interference fit. Heat the ring gear enough to
expand it and hit it with a hammer to remove it evenly.

Clean the outer surface of the flywheel to give it a smooth

fit.

P115950 Clean the new ring gear and heat it to a maximum

temperature of 220°C (428°F).

Remove the bolts (Item 1) [Figure 70-140-1] from the NOTE: The lead chamfer on ring gear tooth must face
flywheel. the starter.

Remove the flywheel from the engine crankshaft. Fit the ring gear over the flywheel. Make sure the gear is
seated properly.
Installation: Apply engine oil to the bolts and tighten to
67,8 N•m (50 ft-lb) torque plus 45° of added rotation in a
crisscross pattern.

Installation: There is an alignment pin (Item 2) [Figure

70-140-1] that is used to install the flywheel in the proper
position for timing purposes.

945 of 1052 70-140-1 T870 Service Manual

FLYWHEEL AND HOUSING (CONT’D) Figure 70-140-4

Housing Removal And Installation

Remove the drive belt. (See Belt Replacement on Page

30-50-2.) 1

Remove the hydrostatic pump. (See Removal And

Installation on Page 30-40-4.)
3
Remove the belt tension pulley assembly. (See Tensioner
Pulley Removal And Installation on Page 30-50-4.)

Remove the flywheel. (See Flywheel Removal And

2
Installation on Page 70-140-1.)
P121047
Remove the starter. (See Removal And Installation on
Page 60-40-1.) Remove the rear oil seal (Item 1) and remove the
flywheel housing bolts (Item 2) [Figure 70-140-4].
Figure 70-140-3
Remove the flywheel housing (Item 3) [Figure 70-140-4].

Installation: Apply Loctite™ 5902 to the assembly

surface of the flywheel housing and tighten the mounting
1 bolts to 22 N•m (16 ft-lb) torque.

2 Figure 70-140-5

3
1 1

2
4
P121046

Remove the mounting bolts (Item 1) and engine mount

(Item 2) [Figure 70-140-3].

P121014A

NOTE: Use rear oil assembly jig (7031370) to install

seal.

Install the rear oil seal (Item 1) to the rear oil seal
assembly jig guide (Item 2) [Figure 70-140-5].

Install the rear oil seal assembly jig guide (Item 1) to the
crankshaft (Item 3) [Figure 70-140-5].

Install the rear oil seal assembly jig holder (Item 4) to the
rear oil seal assembly jig guide (Item 2) [Figure 70-140-
5].

Tighten the center bolt on the rear oil seal assembly jig
holder (Item 4) to install the rear seal (Item 1) [Figure 70-
140-5].

946 of 1052 70-140-2 T870 Service Manual

EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Description

Exhaust Gas Recirculation (EGR) system circulates some of the exhaust gas from the engine to the intake side, cools the
gas and then delivers the cooled gas to the engine for re combustion in order to reduce NOx emission.

To reduce NOx emission from the engine, EGR circulates the exhaust gas of which oxygen concentration is very little to
the intake system. As a result, low temperature combustion occurs in the engine and the NOx emission is reduced.

The EGR cooler is used to reduce NOx emission and enhance engine combustion efficiency by reducing temperature of
high-temperature exhaust gas.

Figure 70-150-1

7
2
5 6
8

10
9

P115965

The air from the air filter (Item 1) is routed to the compressor side (Item 2) of the turbo charger. The compressed air then
flows through the inter cooler (Item 3) to the intake manifold (Item 5) and combustion chamber. Some of the exhaust gas
(Item 6) flows through the EGR valve (Item 7), through the EGR cooler (Item 4) and mixes with the air from the inter cooler
(Item 3). The remaining exhaust gas flows through the turbine (Item 8) side of the turbo charger, through the muffler (DOC)
(Item 9) and out the muffler tail pipe (Item 10) [Figure 70-150-1].

947 of 1052 70-150-1 T870 Service Manual

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Figure 70-150-3
(CONT'D)

Removal And Installation

1 1
WARNING
AVOID BURNS 3
Some surfaces of the Exhaust Gas Recirculation
system can be hot. Use caution when conducting
diagnostic tests. 2

Allow the engine to cool before servicing.

W-2716-0208 P121141

Allow the engine to cool before working on the EGR Remove the bolts (Item 1), reposition the clamp (Item 2)
system. and remove the drain tube assembly (Item 3) [Figure 70-
150-3].
Installation: When reassembling replace with new
gaskets. Installation: Tighten the bolts to 9,8 N•m (7.2 ft-lb)
torque.
Figure 70-150-2
Figure 70-150-4
1

2 2

1
1
2 1

1 3
1

P121140

P115966

Remove the oil tube line bolts (Item 1) and the oil tube
line (Item 2) [Figure 70-150-2].
Remove the bolts (Item 1) and disconnect the EGR pipes
(Item 2) [Figure 70-150-4].
Installation: Tighten the bolt to 19,6 N•m (14.5 ft-lb)
torque.
Remove the coolant hoses (Item 3) [Figure 70-150-4].
NOTE: The oil delivery pipe and copper washers are
single use parts and should be replaced
whenever the oil delivery pipe and copper
washers are removed.

948 of 1052 70-150-2 T870 Service Manual

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Figure 70-150-6
(CONT'D)

Removal And Installation (Cont’d)

Figure 70-150-5

3
4
1
4 2

P115968
1
3 Remove the retaining bolts (Item 1) [Figure 70-150-6].

P115967 Remove the EGR valve (Item 2), the EGR cooler (Item 3)
and the gasket (Item 4) [Figure 70-150-6].

Remove the two retaining bolts (Item 1) [Figure 70-150- Installation: When reassembling replace with new
5] from the EGR mount. gaskets. Torque the bolts to 9,8 N•m (7.2 ft-lb).

Remove the three retaining bolts (Item 2) [Figure 70-

150-5].

Remove the coolant hose (Item 3) and the EGR valve

assembly (Item 4) [Figure 70-150-5].

Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.

949 of 1052 70-150-3 T870 Service Manual

950 of 1052 70-150-4 T870 Service Manual
DIESEL EXHAUST FLUID (DEF) / ADBLUE® SYSTEM Filling The DEF / AdBlue® Tank

Description Stop the engine.

The engine exhaust system is equipped with a selective NOTE: The engine must be stopped with the key
catalytic reduction (SCR) system. The SCR is an switch in the STOP position when filling the
emissions reduction system that removes nitrogen oxides DEF / AdBlue® tank.
from the exhaust gases.
Figure 70-160-1
The machine will periodically perform a process to clean
sulfur oxides from the SCR system. This process is
called DeSOX. (See SELECTIVE CATALYTIC
REDUCTION (SCR) SYSTEM on Page 70-30-1.)

The SCR system requires Diesel Exhaust Fluid (DEF) /

AdBlue® to function correctly. 1

NOTE: Diesel exhaust fluid (DEF) and AdBlue® are

different names for the same fluid.

The SCR system will use one tankful of DEF / AdBlue®

for approximately two to four tankfuls of diesel fuel.

The DEF / AdBlue® level indicator is located on the left

P121093
panel. (See Left Panel on Page 60-50-1.)

The DEF / AdBlue® fill cap is located on the left side of

the machine. Remove the fill cap (Item 1) [Figure 70-
160-1].

Add only clean, unused DEF / AdBlue®. (See Capacities

on Page SPEC-10-5.)

Install and tighten the fill cap (Item 1) [Figure 70-160-1].

NOTE: The DEF / AdBlue® fill cap must be tightened

until the cap clicks.

951 of 1052 70-160-1 T870 Service Manual

952 of 1052 70-160-2 T870 Service Manual
 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
AC System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Air Conditioning Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-3
Air Conditioning Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-3
Air Conditioning Service Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-4
Evaporator / Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-5

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
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-8
HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-9
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-10
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-16
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-17

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 Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-3
Schrader® Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-4

EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1

953 of 1052 80-01 T870 Service Manual

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

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

EVAPORATOR / HEATER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1

954 of 1052 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 AC System Diagram 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 AC System Diagram 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 AC System Diagram 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 AC System Diagram
on Page 80-10-2.)

The expansion valve meters the amount of refrigerant entering the evaporator coil (Item 5) (See AC System Diagram 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 AC System Diagram 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 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.

955 of 1052 80-10-1 T870 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D)

AC System Diagram

Thermostat
Cold Air
Evaporator

5
Evaporator
4
Expansion Valve

Blower
6

1 Compressor

2 Condenser

Pressure
Switch
Sight
Glass

Fan
Desiccant
3 Receiver Drier

Status Of R-134a_______________________________________________

High Pressure Gas Low Pressure Liquid

High Pressure Liquid Low Pressure Gas

b-16691

956 of 1052 80-10-2 T870 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-3

Components

Figure 80-10-1
1

P114493A

Receiver / Drier: The receiver / drier (Item 1) [Figure 80-

P121174 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
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

P100889

Heater / Evaporator Unit: The heater / evaporator unit

(Item 1) [Figure 80-10-4] is located behind the loader
cab. The unit delivers the cold air for the A/C and warm
air for heat into the cab. The unit contains the blower,
heat and A/C coils, thermostat and expansion valve.
P121216A

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.

957 of 1052 80-10-3 T870 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-7

Components (Cont'd)
1
Figure 80-10-5

2
3
4

P-92638
1

Control Panel: The panel (Item 1) [Figure 80-10-7] has

P100878 three separate components.

Fan Switch: This is a four position rotary switch (Item 2)

Expansion Valve: The expansion valve (Item 1) [Figure [Figure 80-10-7]. When the fan switch is in the off
80-10-5] controls the amount of refrigerant entering the position the A/C will not engage, but the heat valve will
evaporator coil. operate, as it is controlled by the key switch.

Figure 80-10-6 A/C Switch: The rocker switch (Item 3) [Figure 80-10-7]
will be illuminated when the A/C is engaged.

2 Potentiometer: The potentiometer (Item 4) [Figure 80-

4 10-7] 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.

3 Figure 80-10-8
1

P101946
1

Evaporator Coil: The evaporator coil (Item 1) [Figure 80-

10-6] cools and dehumidifies the air before it enters the
cab.

Thermostat: The thermostat (Item 2) [Figure 80-10-6]

controls the temperature of the evaporator coil.
P101968

Heater Coil: The heater coil (Item 3) [Figure 80-10-6]

supplies the warm air into the cab by passing air through Heater Valve: The heater valve (Item 1) [Figure 80-10-8]
the coil. is used to control the amount of engine coolant that flows
to the heater coil.
Heater / Evaporator Blower: The blower (Item 4) [Figure
80-10-6] is used to push air through the heater and
evaporator coils and into the cab.

958 of 1052 80-10-4 T870 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D)

Components (Cont'd)

Figure 80-10-9

P114492A

Pressure Switch: The pressure switch (Item 1) [Figure

80-10-9] 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
(193 bar) (28 psi) or less on the high side, which
indicates loss of refrigerant.

NOTE: There is a Schrader valve in the receiver /drier

to allow the pressure switch to be changed
without evacuating the A/C system.

959 of 1052 80-10-5 T870 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D)

Safety Equipment WARNING

Figure 80-10-10
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611

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 80-10-11] to prevent frost bite if you
should get refrigerant on your hands.
P16398
NOTE: Do Not use cotton gloves as the cotton fibers
can get into the system and cause damage.
Figure 80-10-11

WARNING
HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-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 R-134a in the air.
P16399
Any servicing work that involves release or addition
of R-134a to the system must be done by a
In servicing A/C and heater systems you will be exposed competent refrigeration dealer who has the proper
to high pressures, temperatures and several chemical equipment, knowledge, and experience to service
hazards. Moving belts and pulleys are normal shop refrigeration equipment.
hazards. W-2373-0611

In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-
10-10] 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.

960 of 1052 80-10-6 T870 Service Manual

REGULAR MAINTENANCE Recirculation Filter

Filters Figure 80-20-2

See the SERVICE SCHEDULE for the correct service

interval. (See SERVICE SCHEDULE on Page 10-70-1.)

Fresh Air Filters

Figure 80-20-1

3 1
P100755

The recirculation filter is located behind the operator’s

2
seat inside the operator cab. The filter cover is held in
1 place with three clips. Pull the cover at each end (Item 1)
[Figure 80-20-2] to remove.

P-90489B
Rinse the filter elements with water or use a vacuum
P-90492A
cleaner to clean. Do not use solvents.

The fresh air filters are located behind the side windows Line up the clips on the filter cover with the slots provided
outside the operator cab. (Right side shown) Remove the and push the cover into position.
retaining screw (Item 3) and the filter cover (Item 2)
[Figure 80-20-1]. (Lift arms shown raised for visual
clarity.)

NOTE: Loosen the upper filter cover bolt (Item 1)

[Figure 80-20-1] to allow removal and
installation of the cover if equipped with the
High-Efficiency Particulate Air (HEPA) filter
kit.

Shake the filter (Item 4) [Figure 80-20-1] or use low

pressure air to remove dirt. This procedure can be done
several times before replacement is required. Install the
filter, the filter cover, and the retaining screw.

NOTE: Do Not use a brush to remove dirt from the

fresh air filter. Brushing will force dirt into the
fibers.

961 of 1052 80-20-1 T870 Service Manual

REGULAR MAINTENANCE (CONT’D) Figure 80-20-3

Compressor Drive Belt Adjustment

The air conditioning belt has a spring loaded idler that

constantly maintains the correct belt tension.This belt
does not require periodic adjustment.

Compressor Drive Belt Replacement

1
Stop the engine and open the rear door.

Figure 80-20-1

P121903

Loosen the fuel filter clamps (Item 1) [Figure 80-20-3].

Remove the fuel filter assembly from the clamps and

1 move clear of the air conditioning compressor belt shield.
2

P121466

Remove the alternator belt shield mounting nuts and

bolts (Item 1) [Figure 80-20-1].

Remove the alternator belt shield (Item 2) [Figure 80-20-

1].

Figure 80-20-2

P121337

Disconnect the electrical connector (Item 1) [Figure 80-

20-2] from the fuel filter.

962 of 1052 80-20-2 T870 Service Manual

REGULAR MAINTENANCE (CONT'D) Figure 80-20-6

Compressor Drive Belt Replacement (Cont’d)

Figure 80-20-4

NA9657

Install new belt using the routing diagram [Figure 80-20-

P121080
6] and remove breaker bar.

NOTE: Verify the belt is properly aligned on each

Remove the air conditioning compressor belt shield pulley.
mounting bolts and nut (Item 2) [Figure 80-20-4].
Install air conditioning compressor belt shield and
Remove the air conditioning compressor belt shield (Item mounting bolts and nut [Figure 80-20-4].
1) [Figure 80-20-4].
Install fuel filter assembly into clamps and tighten clamps
Figure 80-20-5 [Figure 80-20-3].

Connect the electrical connector (Item 1) [Figure 80-20-

2] to the fuel filter.

Install the alternator belt shield, mounting bolts, and nuts

[Figure 80-20-1].

Close the rear door.

1
Air Conditioning Condenser

The condenser should be cleaned with the hydraulic fluid

cooler and radiator assembly. (See Cleaning on Page 10-
90-1.)
P121079
Air Conditioning Lubrication
Insert breaker bar into the hole provided in the idler Operate the air conditioning for about 5 minutes every
pulley (Item 1) [Figure 80-20-5] and push down to week to lubricate the internal components.
release belt tension. Remove the belt from the pulleys.

Inspect the pulleys for wear.

963 of 1052 80-20-3 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:

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:

964 of 1052 80-20-4 T870 Service Manual

REGULAR MAINTENANCE (CONT’D) Figure 80-20-9

Evaporator / Heater Coil

See the SERVICE SCHEDUAL for the correct service

interval. (See SERVICE SCHEDULE on Page 10-70-1.)
1
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-1.)

Figure 80-20-7

2
P109544

1 Clean the plenum drains (Item 1) [Figure 80-20-9] to

ensure they are not plugged by debris.

Inspect the cover seal (Item 2) [Figure 80-20-9] for

breaks and tears. Ensure the seal is firmly attached all
around the cover.

P100756 Figure 80-20-10

Unhook cover latches (Item 1) [Figure 80-20-7] and

remove the cover.
2
Figure 80-20-8

P109411

2
NOTE: The bosses (Item 1) fit inside the core
supports (Item 2) [Figure 80-20-10] when the
cover is installed. Deformity of the cover
P100757 indicates they are out of position.

Use low pressure air or water to remove debris from the

heater coil (Item 1) and evaporator (Item 2) [Figure 80-
20-7].

965 of 1052 80-20-5 T870 Service Manual

REGULAR MAINTENANCE (CONT’D) Figure 80-20-13

Evaporator / Heater Coil (Cont’d)

NOTE: Improper cover installation can damage the

seal, which may lead to HVAC component
failure. Perform the following steps in the
order given to prevent cover seal damage.

Figure 80-20-11 1

P100756

3. Fasten the two remaining latches (Item 1) [Figure 80-

20-13].

NOTE: Perform a thorough visual check to ensure

that the cover and the cover seal are not
deformed. The cover should seal tightly all
P109546
around without any gaps.

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

1. Hold the cover in place and fasten two latches (Item
1) [Figure 80-20-11].

Figure 80-20-12

1 2 3

P109543A P109545

2. Push the cover up in three places (Items 1, 2, and 3)

until the slots snap into place on the tabs. This slot
(Inset) [Figure 80-20-12] is correctly fastened.

966 of 1052 80-20-6 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 thermostat switch Check thermostat using a circuit tester. Replace thermostat.
(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 suction Repair any leaks and recharge
pressure will be low. 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.
3. Defective heater valve A/C temperature rises as engine temperature Pinch off heater valve. If A/C
rises. temperature lowers, replace
heater valve.

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 The compressor is locked up and the belt slips. Replace compressor.
malfunction.
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.

967 of 1052 80-30-1 T870 Service Manual

TROUBLESHOOTING (CONT'D)

The Compressor Does Not Operate At All, Or Operates Improperly (Cont’d)

Possible Cause Inspection Solution

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.

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 than the low side pressure.

Possible Cause Inspection Solution

Low pressure side Too The low side pressure normally becomes too high when
high. the high 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. Repair any leaks and recharge
charge. the refrigerant to the correct
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. Suction pressure Valve.
will be low.
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.

968 of 1052 80-30-2 T870 Service Manual

TROUBLESHOOTING (CONT'D)

Gauge Pressure Related Troubleshooting (Cont'd)

Possible Cause Inspection Solution

High pressure side Too
high.
1. Poor condenser perfor- Dirty or clogged condenser fins. Condenser fans not Clean fins, and / or repair
mance. operating. the fan.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture
excess refrigerant. Charge
to the correct refrigerant
level.
3. Excessive oil charge. The high pressure side will be high. *Evacuate system. Remove
oil from condenser and
compressor. Measure oil
from compressor 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, con- High pressure side will be high, and low pressure side *Evacuate and flush system
denser or high pressure will be low. replacing defective parts.
line.
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.

* Per MCC, when warranty system, system must reach 100 microns to properly evacuate contamination and moisture.

969 of 1052 80-30-3 T870 Service Manual

TROUBLESHOOTING (CONT'D)

Troubleshooting Tree

P100890

970 of 1052 80-30-4 T870 Service Manual

TROUBLESHOOTING (CONT'D)

Troubleshooting Tree (Cont’d)

p100892

971 of 1052 80-30-5 T870 Service Manual

TROUBLESHOOTING (CONT'D)

Troubleshooting Tree (Cont’d)

P-90413

972 of 1052 80-30-6 T870 Service Manual

TROUBLESHOOTING (CONT'D)
Temperature / Pressure Chart

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
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

Evaporator (Low Pressure)

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 -13°- - 12°C (8 - 10°F) to the temperature on the chart.

Example: Internal Temperature Temperature = 30°F

30°F
+8°F
38°F surface temperature = 33.17 psig

Condenser (High Pressure)

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 = 90°F

90°F
+40°F
130°F condenser temperature = 200 psig

Conditions and pressures will vary from system to system. Check with MCC for system specifications.

973 of 1052 80-30-7 T870 Service Manual

TROUBLESHOOTING (CONT'D) The louver temperature should be between 7.2 - 11.7°C
(45 - 53°F) depending on the amount of humidity in the
Poor A/C Performance air and ambient temperature.

Start the loader, lock the park brake, and engage the A/C If louver temperature is too high. (See Troubleshooting
system with the blower fan on High. Run the loader at full Tree on Page 80-30-4.)
rpm for approximately 15 minutes, with the loader cab
door closed. Check the blower for proper operation, or noise, and
replace if necessary. (See Removal And Installation on
Figure 80-30-1 Page 80-130-1.)

Check the A/C condenser for contamination and clean if

necessary. (See Removal And Installation on Page 80-
60-1.)
1
Check the A/C evaporator coil for contamination and
clean if necessary. (See Removal And Installation on
Page 80-110-1.)

Check the engine coolant to see if it is bypassing the

heater valve. (See Engine Coolant Bypassing The Heater
Valve on Page 80-30-16.)

P-90356B

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].

974 of 1052 80-30-8 T870 Service Manual

TROUBLESHOOTING (CONT'D)

HVAC Repair And Leaks

Figure 80-30-3

P121243

Whenever the A/C system is opened to the atmosphere

or there has been a leak in the system, the receiver /
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.

975 of 1052 80-30-9 T870 Service Manual

TROUBLESHOOTING (CONT’D) Open the rear door (tailgate).

Electrical System Figure 80-30-6

Check to see if the compressor clutch is engaging.

With an operator in the loader seat and the cab door 1

open, turn the loader key switch to RUN, without starting
the loader.

Figure 80-30-4

P121246

2 Locate the loader harness and the compressor clutch

1 wire (Item 1) [Figure 80-30-6].

Disconnect the loader harness (Item 1) [Figure 80-30-6]

from the compressor clutch wire.
P-92638
Figure 80-30-7

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

P121247
1

With a multimeter, check the continuity to the compressor

clutch (Item 1) [Figure 80-30-7].

If there is no continuity, replace the compressor clutch.

P109659

If the compressor clutch does not engage, check the

HVAC fuse (Item 1) [Figure 80-30-5] located in the fuse
panel.

976 of 1052 80-30-10 T870 Service Manual

TROUBLESHOOTING (CONT’D) Figure 80-30-10

Electrical System (Cont’d)

Figure 80-30-8

P121245

1
Using a multimeter check the loader wiring harness (Item
P121247 1) [Figure 80-30-10] for voltage.

The voltage should be battery voltage.

With a multimeter, 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
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.

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

Figure 80-30-9

P121245

If there is voltage at the harness, check the continuity at

the pressure switch (Item 1) [Figure 80-30-11].
1
If there is no continuity, check for low refrigerant level.
(See Reclamation And Charging With Recovery /
Charging Unit on Page 80-40-2.)
P121244

If a continuity is seen, the pressure switch is good.

Locate the loader harness and the pressure switch wire
(Item 1) [Figure 80-30-9]. Reconnect the loader harness to the pressure switch.

Disconnect the loader harness (Item 1) from the pressure

switch wire (Item 2) [Figure 80-30-9].

977 of 1052 80-30-11 T870 Service Manual

TROUBLESHOOTING (CONT’D) Figure 80-30-14

Electrical System (Cont’d)

Figure 80-30-12

1 P-90363A

Disconnect the blower wiring connector (Item 1) [Figure

P100951A 80-30-14] from the loader wiring harness.

Figure 80-30-15
Disconnect the thermostat wiring connector (Item 1)
[Figure 80-30-12] from the loader wiring harness.

Figure 80-30-13

1
2 P-90362A

1
Check the loader harness (Item 1) [Figure 80-30-15] for
P-90362A voltage. The voltage should be battery voltage.

Check the loader harness (Item 1) [Figure 80-30-13] for If there is no voltage at the wiring harness, check the
voltage. The voltage should be battery voltage. harness for broken wires.

If there is no voltage at the wiring harness, check the If there is voltage at the wiring harness, check for
harness for broken wires. continuity to the blower at the blower wiring connector
(Item 2) [Figure 80-30-15].
If there is voltage at the wiring harness, check the
thermostat (Item 2) [Figure 80-30-13] for resistance. If there is no continuity, replace the blower. (See Removal
And Installation on Page 80-130-1.)
The resistance value of the thermostat should be 10 ohm
at 20°C (68°F). If there is a continuity, check the climate controls at 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.

978 of 1052 80-30-12 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 continuity.

With the switch in the 1 position, there should be

Remove the control panel (Item 1) [Figure 80-30-16] continuity between C terminal and the B terminal. And
from the left side lower panel. also between the C terminal and the L terminal frame
[Figure 80-30-18].
Figure 80-30-17
With the switch in the 2 position, there should be
continuity 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

continuity 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 continuity tests fail, replace the blower

switch.

If the above continuity 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.

979 of 1052 80-30-13 T870 Service Manual

TROUBLESHOOTING (CONT’D) If no continuity is found, replace the A/C switch.

Electrical System (Cont’d) If a continuity 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.

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 continuity.

With the switch in the OFF position there should be no

continuity between any of the three terminals on the A/C
switch.

With the switch in the ON position there should be

continuity between terminal (Item 1) and terminal (Item 2)
[Figure 80-30-20].

980 of 1052 80-30-14 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
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.

981 of 1052 80-30-15 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 10-20-2.)
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
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 key 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 -
C 7217666 on Page 10-61-1.)
A
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-90371A
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 replaced.

982 of 1052 80-30-16 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 10-20-2.)

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
P-90364A 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
Push the A/C switch (Item 1) to the OFF position, turn the starting the loader. The heater valve should rotate. Place
blower switch (Item 2) to position 1 and turn the a mark on the loader valve shaft.
temperature control (Item 3) [Figure 80-30-29] to the
High A/C position, with the loader key 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 key switch
7217666 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 80-30-10.)

Replace the heater valve. (See Removal And Installation

on Page 80-140-1.)

983 of 1052 80-30-17 T870 Service Manual

984 of 1052 80-30-18 T870 Service Manual
SYSTEM CHARGING AND RECLAMATION Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.)
Refrigerant Identification
Raise the operator cab. (See Raising on Page 10-30-1.)

Connect the Refrigerant Identifier to the low pressure

WARNING hose.

Connect the Refrigerant Identifier to its power source.

In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
Follow the steps displayed on the refrigerant identifier
contact with a flame, R-134a refrigerant gives a toxic
screen.
gas.
W-2371-0611
Allow two minutes for the refrigerant identifier to display
the type of refrigerant and air content. An alarm will
Figure 80-40-1 sound if potentially flammable hydrocarbons are present
and will also indicate on the visual display.
1
Disconnect the refrigerant identifier from the loader A/C.

If the refrigerant is dangerous or flammable, it must be

evacuated from the A/C system into a separate container
and properly and safely disposed of.

When changing components:

1. Discharge system

2. Replace components
N-23024
3. Evacuate to 1000 microns to check for leaks and to
remove moisture
NOTE: It is recommended to identify the type of
refrigerant that is in the A/C system and if it is 4. Charge system
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.

985 of 1052 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 10-20-2.)

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
P100895
HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
Locate the low pressure port (Item 1), and high pressure blindness if it contacts the eyes and may cause
port (Item 2) [Figure 80-40-2]. serious frostbite if it contacts the skin.
• Gaseous R-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 R-134a in the air.
Any servicing work that involves release or addition
In the event of a leak, wear safety goggles. Escaping of R-134a to the system must be done by a
refrigerant can cause severe injuries to eyes. In competent refrigeration dealer who has the proper
contact with a flame, R-134a refrigerant gives a toxic equipment, knowledge, and experience to service
gas. refrigeration equipment.
W-2371-0611 W-2373-0611

Use an approved recovery / charging unit [Figure 80-40-

3] to evacuate the system.

986 of 1052 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
1
2

1
P100950

Connect the reclaimer to the loader A/C charge ports

[Figure 80-40-5].
P127692
Connect the Blue hose (Item 1) [Figure 80-40-6] to the
low pressure port and open the valve.
Using a tee connector, connect the micron gauge (Item 1)
[Figure 80-40-4] inline to the Red high pressure hose. Connect the Red hose (Item 2) [Figure 80-40-6] to the
high pressure port and open the valve.
Figure 80-40-5
Figure 80-40-7

P100385

N-22292

Turn the reclaimer unit [Figure 80-40-7] to the ON

position and follow the on screen instructions.

NOTE: Recharge the A/C system to the specified

capacity. (See Capacities on Page SPEC-10-
5.)

987 of 1052 80-40-3 T870 Service Manual

SYSTEM CHARGING AND RECLAMATION (CONT'D)

Reclamation And Charging With Recovery / Charging

Unit (Cont'd)

Figure 80-40-8

N-22381

NOTE: The reclaimer unit, has a complete step by

step set of instructions [Figure 80-40-8] to
follow for reclamation and recharging of the
A/C system. A trained technician should
follow these instructions as they may vary
slightly depending on the model and brand of
reclaimer used.

988 of 1052 80-40-4 T870 Service Manual

COMPRESSOR Figure 80-50-3

Removal And Installation

1
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. 2

Evacuate the A/C system. (See Reclamation And

Charging With Recovery / Charging Unit on Page 80-40-
2.)

Open the rear door.

Figure 80-50-1
P121080

Remove the air conditioning compressor belt shield

1 mounting bolts and nut (Item 2) [Figure 80-50-3].

Remove the air conditioning compressor belt shield (Item

1) [Figure 80-50-3].

Figure 80-50-4

P121246

Disconnect the loader harness (Item 1) [Figure 80-50-1] 2

from the compressor clutch wire.

Figure 80-50-2

P121090A

Remove the nuts and bolts (Item 1) and the alternator

shield (Item 2) [Figure 80-50-4].
2

P121903

Disconnect the water in fuel sensor (Item 1) and loosen

the fuel filter clamps (Item 2) [Figure 80-50-2].

Remove the fuel filter assembly from the clamps and

move clear of the air conditioning compressor belt shield.

989 of 1052 80-50-1 T870 Service Manual

COMPRESSOR (CONT'D) Figure 80-50-6

Removal And Installation (Cont’d)

Figure 80-50-5
2

3
1

P121276

Remove the compressor hoses (Item 1) [Figure 80-50-6]

from the compressor.
P121079

Installation: Tighten the compressor hose (Item 2) to 46

Insert breaker bar into the hole provided in the idler N•m (34 ft-lb) torque.
pulley (Item 1) [Figure 80-50-5] and push down to
release belt tension. Remove the belt from the pulleys. Installation: Tighten the compressor hose (Item 3) to 30
N•m (22 ft-lb) torque.

Cap and plug the compressor hoses and the fittings with
WARNING the proper A/C caps and plugs.

Figure 80-50-7
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611

P121278A

Remove the compressor mounting bolts (Item 1) [Figure

80-50-7] top and bottom (top shown).

Remove the compressor from the loader.

990 of 1052 80-50-2 T870 Service Manual

COMPRESSOR (CONT'D) The compressor oil should be checked as follows when
oil is being added to an in service loader.
Oil
There is a close affinity between oil and refrigerant.
Figure 80-50-8 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.
1
If the amount of refrigerant in the system has decreased,
charge the system. (See SYSTEM CHARGING AND
RECLAMATION on Page 80-40-1.)

Open the cab door and windows.

Run the blower at maximum speed.

Run the compressor for at least 20 minutes at 800 - 1200

P121174 rpm.

Remove the compressor from the loader. (See Removal

The compressor (Item 1) [Figure 80-50-8] is factory filled And Installation on Page 80-50-1.)
with 115 - 155 cc's of PAG 46 oil (Poly Alkelene Glycol).

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 46 oil should be used, and never

mix R-12 and R-134a Oils.

991 of 1052 80-50-3 T870 Service Manual

COMPRESSOR (CONT'D) Figure 80-50-11

Oil Check

Figure 80-50-9

1
1
P121272

Add the same amount of new compressor oil that was

P121272 removed through the suction side connector (Item 1)
[Figure 80-50-11].

Drain the oil through the connectors (Item 1) [Figure 80- NOTE: The suction port on the compressor is marked
50-9]. with an SUC and is the larger port on the
compressor.
Figure 80-50-10

P121174

NOTE: After draining the oil, extract the remaining oil

through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-50-
10] several times by hand.

Measure the drained oil in a measuring cylinder.

Inspect the oil for contamination, dirt, metal shavings, or

varnish color.

NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.

992 of 1052 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 10-20-2.) 1
Raise the operator cab. (See Raising on Page 10-30-1.)

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
Unit on Page 80-40-2.)
P114505

WARNING Unhook the two rubber straps (Item 1) [Figure 80-60-2].

Figure 80-60-3
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611

1
Figure 80-60-1

1
1

P121217A

Raise the air conditioning condenser (Item 1) [Figure 80-

60-3].

NOTE: The air conditioning condenser fits into two

P121216A slotted brackets mounted on the hydraulic
fluid cooler and radiator assembly. Ensure the
air conditioning condenser remains
Remove the two hoses (Item 1) [Figure 80-60-1]. connected to the brackets when raising and
lowering.
Cap and plug the hose and the condenser fittings with
the proper A/C caps and plugs.

Installation: Tighten the hose (Item 1) [Figure 80-60-1]

to 30 N•m (22 ft-lb) torque.

993 of 1052 80-60-1 T870 Service Manual

CONDENSER (CONT’D)

Removal And Installation (Cont’d)

Figure 80-60-4

1
2

P121248

Remove the clips (Item 1) [Figure 80-60-4] and lift the

condenser out of the machine.

Installation: Ensure the air condenser is installed into

the two slotted brackets [Figure 80-60-4] (left side
shown).

Ensure the clips (Item 1) are properly installed over the

two slotted brackets (Item 2) [Figure 80-60-4] (left side
shown).

Figure 80-60-5

P114505

Fasten the two rubber straps (Item 1) [Figure 80-60-5]

(right side shown).

994 of 1052 80-60-2 T870 Service Manual

RECEIVER / DRIER Installation: Tighten the two A/C hoses (Item 1) [Figure
80-70-1] to 30 N•m (22 ft-lb) torque.
Receiver / Drier Removal And Installation
Both fittings on the drier are the same size, so the hoses
can be hooked up incorrectly.

WARNING Cap and plug the hoses and the receiver / drier fittings
with the proper A/C caps and plugs.
Never work on a machine with the lift arms up unless
NOTE: When replacing a receiver / drier in an A/C
the lift arms are secured by an approved lift arm
system 30 cc of PAG 100 oil must be added to
support device. Failure to use an approved lift arm
the system when recharging.
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
Figure 80-70-2

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
Unit on Page 80-40-2.)

WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In P115342

contact with a flame, R-134a refrigerant gives a toxic

gas.
Note the flow direction on the receiver / drier (Item 1)
W-2371-0611
[Figure 80-70-2] for proper installation.

Figure 80-70-1

P114493A

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.

995 of 1052 80-70-1 T870 Service Manual

RECEIVER / DRIER (CONT’D)

Receiver / Drier Removal And Installation (Cont’d)

Figure 80-70-3

P114491A

Loosen the two clamps (Item 1) and remove the receiver /

drier (Item 2) [Figure 80-70-3].

Figure 80-70-4

P114490A

Remove the two mount bolts (Item 1) [Figure 80-70-4]

from the receiver / drier mount bracket.

996 of 1052 80-70-2 T870 Service Manual

RECEIVER / DRIER (CONT’D) Figure 80-70-6

Pressure Switch Removal And Installation

Figure 80-70-5 1

P114492A

Remove the pressure switch (Item 1) [Figure 80-70-6]

P114503 from the receiver / drier.

Remove the pressure switch from the loader.

Disconnect the loader wire harness (Item 1) [Figure 80-
70-5] from the pressure switch wire harness.

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, R-134a refrigerant gives a toxic
gas.
W-2371-0611

997 of 1052 80-70-3 T870 Service Manual

RECEIVER / DRIER (CONT’D)

Schrader® Valve Removal And Installation

Figure 80-70-7

P115343

The Schrader® valve (Item 1) [Figure 80-70-7] is located

in the receiver / drier under the 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.

998 of 1052 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 10-20-2.)

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

2 1 2
Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 80-40-
2.)

Figure 80-80-1

P100900A
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].

Figure 80-80-4
1

3
P100879A 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)

P100879A 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].

999 of 1052 80-80-1 T870 Service Manual

1000 of 1052 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 5. Temperature sensor open and short detection
startup 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 open or
temperature is below -2°C (28.4°F), the EDT will turn off short detection
the clutch and status LED.
Clutch circuit At A/C startup 2x per second
open, short or
Figure 80-90-1
over current
Compressor Continuous 3x per second
clutch short to
ground

NOTE: When the status LED is flashing, it does NOT

1 mean the module is OFF. It may restart in
approximately 20 seconds. Keep away from
all rotating parts to prevent injury.

The EDT is able to detect short circuit from clutch output

to ground. When a short is detected, the output will be
turned off and turning back on in approximately 20
seconds while the status LED will flash to indicate there
P-90576 is a malfunction.

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.

1001 of 1052 80-90-1 T870 Service Manual

THERMOSTAT (CONT’D)

Removal And Installation

Remove the evaporator / heater cover. (See Removal on

Page 80-150-1.)

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.

Figure 80-90-2

P100894

Remove the thermostat probe (Item 1) [Figure 80-90-2]

from the A/C evaporator coil.

Figure 80-90-3

P100893

Remove the thermostat (Item 1) from the evaporator /

heater unit [Figure 80-90-3].

1002 of 1052 80-90-2 T870 Service Manual

EXPANSION VALVE Figure 80-100-2

Removal And Installation

Evacuate the A/C system. (See Reclamation And

Charging With Recovery / Charging Unit on Page 80-40-
2.)

Remove the evaporator / heater cover. (See Removal on

2
Page 80-150-1.)

WARNING
1
P101948
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic NOTE: The evaporator / heater unit is removed for
gas. photo clarity.
W-2371-0611

Remove the two evaporator fittings (Item 1) [Figure 80-

Figure 80-100-1 100-2] from the expansion valve.

Installation: Tighten the two evaporator fittings to 30

N•m (22 ft-lb) torque.

Remove the two mount bolts (Item 2) [Figure 80-100-2].

Remove the expansion valve from the loader.

Cap and plug the evaporator tubelines (Item 1) [Figure

1 80-100-2] and the expansion valve fittings with the proper
1
A/C caps and plugs.

Figure 80-100-3

P103082

Remove the two A/C hoses (Item 1) [Figure 80-100-1]

from the expansion valve.

Installation: Tighten the two A/C hose fittings to 30 N•m

(22 ft-lb) torque.

Cap and plug the hoses and the expansion valve fittings
with the proper A/C caps and plugs.

N-22085

The expansion valve [Figure 80-100-3] is replaced as a

complete unit.

1003 of 1052 80-100-1 T870 Service Manual

1004 of 1052 80-100-2 T870 Service Manual
EVAPORATOR COIL Figure 80-110-2

Removal And Installation

Evacuate the A/C system. (See Reclamation And

Charging With Recovery / Charging Unit on Page 80-40-
2.) 2 2
3
Remove the evaporator / heater cover. (See Removal on
Page 80-150-1.)

1
WARNING
P100757
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic Remove the thermostat probe (Item 1) [Figure 80-110-2]
gas. from the evaporator coil.
W-2371-0611

Remove the two retaining clips (Item 2) [Figure 80-110-

Figure 80-110-1 2] that connect the evaporator coil, to the heater coil.

Remove the evaporator coil (Item 3) [Figure 80-110-2].

Figure 80-110-3

1
P101948

NOTE: The evaporator / heater unit is removed for

photo clarity. P-90424

Disconnect the two evaporator fittings (Item 1) [Figure

80-110-1] from the expansion valve. Inspect the evaporator coil [Figure 80-110-3] for leaks,
and replace as needed.
Installation: Tighten the two evaporator fittings to 29,8
N•m (22 ft-lb) torque. Clean with low pressure water or air.

Cap and plug the evaporator tubelines (Item 1) [Figure

80-110-1] and the expansion valve fittings with the proper
A/C caps and plugs.

1005 of 1052 80-110-1 T870 Service Manual

1006 of 1052 80-110-2 T870 Service Manual
HEATER COIL Figure 80-120-3

Removal And Installation

Remove the evaporator / heater cover. (See Removal on

Page 80-150-1.)

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.
P100946
Figure 80-120-1

Remove the two bolts (Item 1) [Figure 80-120-3].

Figure 80-120-4

1
1

P100944

Remove the two screws (Item 1) [Figure 80-120-1].

P100947
Figure 80-120-2

Remove the two bolts (Item 1) [Figure 80-120-4].

Remove the heater coil from the unit.

P101947

Remove the retainer clips (Item 1) [Figure 80-120-2]

from both sides.

1007 of 1052 80-120-1 T870 Service Manual

HEATER COIL (CONT'D)

Removal And Installation (Cont'd)

Figure 80-120-5

P100945

The heater coil [Figure 80-120-5] can be cleaned with

low pressure air or water.

1008 of 1052 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

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].

1009 of 1052 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.

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.

1010 of 1052 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-
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.

1011 of 1052 80-130-3 T870 Service Manual

1012 of 1052 80-130-4 T870 Service Manual
HEATER VALVE Figure 80-140-2

Removal And Installation

Remove the evaporator / heater cover. (See Removal on

Page 80-150-1.)
2
NOTE: The heater valve is not serviceable and must
be replaced as a complete assembly. 1

Remove any tie-straps that hold the heater hoses.

NOTE: The evaporator / heater unit is shown

removed for photo clarity.

Figure 80-140-1 P100948

NOTE: Cap the heater hoses and the heater valve

with plugs to prevent coolant loss from the
1
system.

Remove the heater hose clamp (Item 1) [Figure 80-140-

2].

Remove the heater hose from the heater valve.

Remove the heater hose clamp (Item 2) [Figure 80-140-

2].

P101961 Remove the heater hose from the heater coil.

Disconnect the loader wiring harness (Item 1) [Figure

80-140-1] from the heater valve.

1013 of 1052 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
system.

Remove the heater hose clamp (Item 1) [Figure 80-140-

3].

Remove the two bolts (Item 2) [Figure 80-140-3].

Remove the heater valve (Item 3) [Figure 80-140-3] from

the evaporator / heater unit.

1014 of 1052 80-140-2 T870 Service Manual

EVAPORATOR / HEATER COVER Installation

Removal NOTE: The evaporator / heater unit is shown

removed for photo clarity.
Raise the lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-2.) Figure 80-150-2

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

2 2
Figure 80-150-1

1
1 1

P109411

The bosses (Item 1) must be nested inside the core

P100756 supports (Item 2) [Figure 80-150-2] when positioning the
cover on the HVAC body.

Unhook cover latches (Item 1) and remove the cover Figure 80-150-3
(Item 2) [Figure 80-150-1].

P109396

NOTE: DO NOT hook the tabs (Item 1) [Figure 80-150-

3] until later. Damage to the seal can occur
allowing water to enter the housing causing
premature internal component failure.

1015 of 1052 80-150-1 T870 Service Manual

EVAPORATOR / HEATER COVER (CONT’D) Figure 80-150-6

Installation (Cont’d)

Figure 80-150-4
1

P109399
2 2

Repeat procedure for other side of cover (Item 1) until

P109397 remaining tabs (Item 2) [Figure 80-150-6] are snapped
into place.

Position the cover (Item 1) and hook the two latches (Item Figure 80-150-7
2) [Figure 80-150-4].

Figure 80-150-5

2
1 1

P109400

P109398 Hook the two remaining latches (Item 1) [Figure 80-150-

7].

Push the corner of the cover (Item 1) until the tab (Item 2) Lower the operator cab. (See Lowering on Page 10-30-
[Figure 80-150-5] snaps into place. 2.)

Remove the lift arm support device and lower the lift
arms. (See Removing on Page 10-20-3.)

1016 of 1052 80-150-2 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-10-3
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6

TECHNICAL SERVICE GUIDE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Engine Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Loader Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
Hydraulic / Hydrostatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2

TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2

HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2

HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1

1017 of 1052 SPEC-01 T870 Service Manual

SERVICE TOOLS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1
Remote Start Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1
Hydraulic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-2
Mainframe And Drive Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-4
Electrical Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-6
Engine Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-7
HVAC Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-12

Certain specification(s) are based on engineering calculations and are not actual measurements.
Specification(s) are provided for comparison purposes only and are subject to change without notice.
Specification(s) for your individual Bobcat equipment will vary based on normal variations in design,
manufacturing, operating conditions, and other factors.

1018 of 1052 SPEC-02 T870 Service Manual

(T870) LOADER SPECIFICATIONS

Machine Dimensions

• Dimensions are given for loader equipped with standard tracks and 84 in. Heavy Duty Construction and Industrial
bucket and may vary with other bucket types.

• Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.

1768 mm 2514 mm
(69.6 in) (99 in)

2108 mm
(83 in)
2153 mm
(84.8 in)
1658 mm
(65.3 in)

98°

4689 mm
(184.6 in)
37°

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)
NA9524

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.

1019 of 1052 SPEC-10-1 T870 Service Manual

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 5863 kg (12925 lb)
Breakout Force – Lift 3230 kg (7121 lb)
Breakout Force – Tilt 3692 kg (8139 lb)
Travel Speed:
Low Range 0 – 10,5 km/h (0 – 6.5 mph)
High Range 0 – 18,3 km/h (0 – 11.4 mph)

Engine

Make / Model Bobcat Engine / 3,4L Bobcat Engine Stage IV

Fuel / Cooling Diesel / Liquid
Horsepower:
– ISO 9249 EEC / SAE J1349 Net 71,5 kW (95.9 hp) @ 2400 rpm
– ISO 14396 Gross 74,6 kW (100.1 hp) @ 2400 rpm
– SAE J1995 Gross 75,6 kW (101.4 hp) @ 2400 rpm
– Rated Power 74,6 kW (100.0 hp) @ 2400 rpm
Torque:
– ISO 9249 EEC / SAE J1349 Net 355,8 N•m (262.4 ft-lb) @ 1600 rpm
– ISO 14396 Gross 375,4 N•m (276.9 ft-lb) @ 1600 rpm
– SAE J1995 Gross 380,3 N•m (280.5 ft-lb) @ 1600 rpm
– Rated Torque 375,0 N•m (276.6 ft-lb) @ 1600 rpm
Low Idle rpm 1050
High Idle rpm 2400
Number of Cylinders 4
Displacement 3409 cm3 (208.0 in3)
Bore / Stroke 98 mm / 113 mm (3.86 in / 4.45 in)
Lubrication Gear Pump Pressure System with Filter
Crankcase Ventilation Closed Breathing
Air Cleaner Dry replaceable paper cartridge with separate safety element
Ignition Diesel – Compression
Air Induction Turbo-Charged and Charged Air Cooled
Engine Coolant Propylene Glycol / Water Mixture
Starting Aid Air intake heater automatically activated as needed in RUN position

1020 of 1052 SPEC-10-2 T870 Service Manual

LOADER SPECIFICATIONS (CONT’D)

Drive System

Main Drive Fully hydrostatic, rubber track drive

Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing
Transmission
hydrostatic motors
Tracks (Tension) Grease cylinder and spring

Controls

Machine Steering Direction and speed controlled by hand operated joystick(s)

Loader Hydraulics:
– Lift and Tilt Controlled by hand operated joystick(s)
– Front Auxiliary Controlled by electrical switch on Right Hand joystick
– Rear Auxiliary (Option) Controlled by electrical switch on Left Hand joystick
Auxiliary Pressure Release Pressure relieved through quick couplers; Push couplers in, hold for 5 seconds
Hand operated speed control, additional foot operated speed control pedal; key-
Engine type start switch or optional Keyless Start Panel or optional Deluxe
Instrumentation Panel and function error shutdown
Two independent hydrostatic systems controlled by two hand operated steering
Service Brake
levers or optional joystick(s)
Secondary Brake One of the hydrostatic transmissions
Spring applied pressure release multi-disc brake activated by manually operated
Parking Brake (Standard)
switch on left instrument panel

1021 of 1052 SPEC-10-3 T870 Service Manual

LOADER SPECIFICATIONS (CONT’D)

Hydraulic System

Pump Type Engine driven, gear type

Pump Capacity – Standard-Flow 87,1 L/min (23.0 U.S. gpm)
Pump Capacity – High-Flow (Option) 138,2 L/min (36.6 U.S. gpm)
System Relief at Quick Couplers 27,2 – 27,9 MPa (272 – 279 bar) (3950 – 4050 psi)
Filter (Hydraulic / Hydrostatic) Replaceable beta 10 micron = 200, drop in element
Filter (Charge) Replaceable beta 10 micron = 200, spin-on element
Double-acting; lift cylinders have cushioning feature on lower, tilt cylinders have
Hydraulic Cylinders:
cushioning feature on dump and rollback
Lift Cylinder (2):
Bore Diameter 88,9 mm (3.50 in)
Rod Diameter 50,8 mm (2.00 in)
Stroke 698,75 mm (27.51 in)
Tilt Cylinder (2):
Bore Diameter 82,6 mm (3.25 in)
Rod Diameter 38,1 mm (1.50 in)
Stroke 388,36 mm (15.29 in)
3-Spool, open center with electric actuator controlled lift with float and tilt;
Control Valve
Electrically controlled auxiliary spool
Fluid Lines SAE Standard tubelines, hoses, and fittings
Hydraulic Function Time:
Raise Lift Arms 5.9 seconds
Lower Lift Arms 4.0 seconds
Bucket Dump 2.9 seconds
Bucket Rollback 2.3 seconds

1022 of 1052 SPEC-10-4 T870 Service Manual

LOADER SPECIFICATIONS (CONT’D)

Electrical System

Alternator Belt driven, 120 amperes, open frame

12 volt, 1000 cold cranking amperes @ -18°C (0°F),
Battery
186 minute reserve capacity @ 25 amperes
Starter 12 volt, gear type, 2,7 kW (3.62 hp)
Gauges:
Engine Coolant Temperature and Fuel Level
Warning lights:
Fuel Level, Seat Belt, Engine Coolant Temperature, Engine Malfunction,
Hydraulic System Malfunction, Diesel Exhaust Fluid (DEF) / AdBlue®, and
General Warning
Indicators:
Diesel Exhaust Fluid (DEF) / AdBlue® Level, BICS™ Functions, Two-Speed, 3-
Point Restraint, and Turn Signals
Data Display:
Operating Hours, Engine rpm, Speed Management Setting, Maintenance Clock
Instrumentation Countdown, Battery Voltage, Service Codes, Engine Preheat Countdown, Lift
and Tilt Compensation Setting, Steering Drift Compensation Setting, and Drive
Response Setting
Other:
Audible Alarm, Lights, and Option / Accessory Switches
Optional Deluxe Instrumentation Panel:
*Additional displays for: Engine rpm, Engine Coolant Temperature, Engine Oil
Pressure, System Voltage, Hydraulic Fluid Temperature, and Hydrostatic Charge
Pressure
*Additional Features Included: Keyless Start, Digital Clock, Job Clock, Password
Lockout, Multiple-Language Display, Help Screens, Diagnostic Capability, and
Engine / Hydraulic Systems Shutdown Function

Capacities

Fuel 122,3 L (32.3 U.S. gal)

Engine Oil with Filter Change 12,6 L (13.3 qt)
Engine Cooling System with Heater 14,4 L (3.8 U.S. gal)
Engine Cooling System without
13,6 L (3.6 U.S. gal)
Heater
Hydraulic / Hydrostatic Reservoir 9,5 L (2.5 U.S. gal)
Hydraulic / Hydrostatic System 45,4 L (12.0 U.S. gal)
Diesel Exhaust Fluid (DEF) /
25,7 L (6.8 U.S. gal)
AdBlue®
Hydrostatic Drive Motor (Each) 180,0 mL (6.1 U.S. fl oz)
Air Conditioning Refrigerant (R-134a) 0,91 kg (2.0 lb)

1023 of 1052 SPEC-10-5 T870 Service Manual

LOADER SPECIFICATIONS (CONT’D)

Tracks

Standard 450 mm (17.7 in) Rubber

Ground Pressure

Rubber Track – 450 mm (17.7 in) 0,033 MPa (0,33 bar) (4.9 psi)

Fuel Consumption

Engine Load Full - 100% High - 70% Medium - 50% Low - 30%
22,0 L 18,5 L 15,1 L 13,6 L
Fuel Consumption Rate Per Hour
(5.8 U.S. gal) (4.9 U.S. gal) (4.0 U.S. gal) (3.6 U.S. gal)
NOTE: The engine fuel consumption chart is to be used as a guideline only. The actual results may vary.

Environmental

DECLARED SINGLE-NUMBER NOISE EMISSION VALUES

In accordance with ISO 4871
Noise level per Directive 2000/14/EC — LwA 104 dB(A)
Operator noise level per Directive 2006/42/EC — LpA 83 dB(A)

DECLARED VIBRATION EMISSION VALUES

In accordance with EN 12096
Value Uncertainty
Whole-body vibration per ISO 2631-1 1,11 m/s2 0,44 m/s2
Hand-arm vibration per ISO 5349-1 2,65 m/s2 1,33 m/s2

Temperature Range

Operation and storage -26 – +43°C (-15 – +110°F)

1024 of 1052 SPEC-10-6 T870 Service Manual

TECHNICAL SERVICE GUIDE SPECIFICATIONS

Engine

Engine Oil Pressure at Low Idle 98 kPa (0,98 bar) (14 psi)
Engine Oil Pressure at High Idle 450 - 600 kPa (4,5 - 6,0 bar) (65 - 87 psi)
Firing Order 1-3-4-2
Location of Number 1 Cylinder Closest to water pump
Crankshaft Rotation (Facing
Clockwise
Crankshaft Pulley)
Valve Clearance (Cold) Intake 0,4 mm (0.016 in)
Valve Clearance (Cold) Exhaust 0,45 mm (0.018 in)

NOTE: For additional engine specifications, (See Specifications on Page 70-10-2.)

Engine Torques

Engine Oil Drain Cap 54 N•m (40 ft-lb)

Fuel Injection Tubeline Nuts 27 - 31 N•m (20 - 23 ft-lb)
Fuel Injector Retaining Bolt 39 - 46 N•m (29 - 34 ft-lb)
Valve Cover Bolts 7 - 8 N•m (5 - 6 ft-lb)
Head Bolts 44 N•m (33 ft-lb) + 90° + 90°
Knock Sensor Bolts 22 N•m (16 ft-lb)

NOTE: For additional engine torques, (See Torque Values on Page 70-10-11.)

Cooling System

Coolant Type and Mix 47% Water and 53% Propylene Glycol
Radiator Cap Pressure 95 kPa (1 bar) (14 psi)
Thermostat Fully Open at 97°C (207°F)

NOTE: For additional cooling system information, (See ENGINE COOLING SYSTEM on Page 70-60-1.)

1025 of 1052 SPEC-20-1 T870 Service Manual

TECHNICAL SERVICE GUIDE SPECIFICATIONS (CONT’D)

Loader Torques

Bob-Tach Pivot Pin Retainer Bolt 446 N•m (330 ft-lb)

Tilt Cylinder Pivot Pin Retainer Bolt 257,6 N•m (190 ft-lb)
Control Valve Mounting Bolts 125 - 135 N•m (90 - 100 ft-lb)
Hydraulic Pump Mounting Bolts 75 - 85 N•m (65 - 70 ft-lb)
Hydrostatic Motor Mounting Bolts 258 N•m (190 ft-lb)
Hydrostatic Pump Pulley Nut 257 - 325 N•m (190 - 240 ft-lb)
Main Frame Mounting Bolts 542 - 583 N•m (400 - 430 ft-lb)
Drive Sprocket 280 - 300 N•m (207 - 220 ft-lb)
Main Frame Mounting Bolts 410 - 450 N•m (300 - 330 ft-lb)

NOTE: Additional loader torques can be found in the relevant section of this manual.

Hydraulic / Hydrostatic System

Pump Capacity at High Idle

- Standard Flow 87,1 L/min (23.0 U.S. gpm)
- High Flow 138,2 L/min (36.6 U.S. gpm)
- Charge 51,1 L/min (13.5 U.S. gpm)
Charge Pressure at High Idle Fluid
Temp at 60°C (140°F): (SJC and 2965 - 3310 kPa (29,65 - 33,1 bar) (430 - 480 psi)
SCPA)
Maximum Cylinder Drift Allowed
33 mm (1.3 in)
Without Bucket in 10 Minutes

NOTE: For additional hydraulic / hydrostatic system information, (See HYDRAULIC SYSTEM INFORMATION on
Page 20-10-1.) and (See HYDROSTATIC SYSTEM INFORMATION on Page 30-10-1.)

Fuel Consumption

Engine Load Full - 100% High - 70% Medium - 50% Low - 30%
22,0 L 18,5 L 15,1 L 13,6L
Fuel Consumption Rate Per Hour
(5.8 U.S. gal) (4.9 U.S. gal) (4.0 U.S. gal) (3.6 U.S. gal)
NOTE: The engine fuel consumption chart is to be used as a guideline only. The actual results may vary.

High - Continuous loading or digging or load / carrying cycles; little idling.

Medium - Average loading or load / carrying cycles; some idling.
Low - Light loading or carrying - not much digging or pushing; considerable idling.

1026 of 1052 SPEC-20-2 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)
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)

1027 of 1052 SPEC-30-1 T870 Service Manual

TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)

Torque For General Metric 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 PROPERTY CLASS

NOM. DIA 8.8 10.9 12.9
- N•m ft-lb N•m ft-lb N•m ft-lb
M4 3,5 - 2,5 2.5 - 2.0 4,2 - 3,8 3.1 - 2.8 5,3 - 4,7 3.9 - 3.5
M5 6,5 - 5,5 5.0 - 4.0 8,4 - 7,6 6.2 - 5.6 9,5 - 8,5 7.0 - 6.2
M6 10,5 - 9,5 7.5 - 7.0 13,7 - 12,3 10.1 - 9.1 15,8 - 14,2 11.6 - 10.4
M7 17 - 15 12.5 - 11.0 22 - 20 16.2 - 14.7 26,3 - 23,7 19.5 - 17.5
M8 26 - 24 19 - 18 32,6 - 29,4 24.0 - 21.7 39 - 35 28.5 - 25.5
M10 47 - 43 35 - 32 63 - 57 46.5 - 42.0 79 - 71 58.5 - 52.5
M12 85 - 75 60 - 55 115 - 105 85 - 78 137 - 123 110 - 91
M14 140 - 125 100 - 90 180 - 160 133 - 118 210 - 190 155 - 140
M16 210 - 190 155 - 140 285 - 255 210 - 188 330 - 300 245 - 225
M18 290 - 260 215 - 190 385 - 345 285 - 255 460 - 420 340 - 310
M20 410 - 370 300 - 275 550 - 490 405 - 360 650 - 590 490 - 440
M22 550 - 500 400 - 370 740 - 760 545 - 560 880 - 800 650 - 590
M24 700 - 640 520 - 470 950 - 850 700 - 625 1120 - 1000 830 - 730
M27 1030 - 930 760 - 680 1370 - 1230 1000 - 900 1630 - 1470 1200 - 1100
M30 1400 - 1260 1030 - 930 1900 - 1700 1400 - 1250 2200 - 2000 1600 - 1500
M33 1900 - 1720 1400 - 1270 2500 - 2300 1850 - 1700 3100 - 2700 2300 - 2000
M36 2450 - 2200 1800 - 1620 3200 - 2900 2400 - 2200 3900 - 3500 2900 - 2600

NOTE: Use the torque value for the part having the lesser property class when a fastener and nut are used
together but have a different property class.

1028 of 1052 SPEC-30-2 T870 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS

Straight Thread O-ring Fitting

Figure SPEC-40-1

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
the washer is tight against the surface [Figure SPEC-40-
1].

Figure SPEC-40-2
O-ring Boss
Tightening Torque
x TORQUE
x N•m
Thread Size (ft-lb)
7/16” - 20 18 (13)
9/16” - 18 30 (22)
3/4” -1 6 54 (40)
7/8” - 14 81 (60)
1-1/16” - 12 114 (84)
1-3/16” - 12 133 (98)
1-5/16” - 12 160 (118)
1-7/16” - 12 209 (154)
1-5/8” - 12 221 (163)

1029 of 1052 SPEC-40-1 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-40-3 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:

Tighten the nut until it makes contact with the seat.

Use the chart [Figure SPEC-40-4] to find the correct

tightness needed. If the fitting leaks after tightening,
disconnect it and inspect the seat area for damage.

Figure SPEC-40-4
Flare Fitting Tightening Torque
Tubeline x TORQUE
Outside x N•m
Diameter Thread Size (ft-lb)
1/4” 7/16” - 20 18 (13)
5/16” 1/2” - 20 23 (17)
3/8” 9/16” - 18 30 (22)
1/2” 3/4” - 16 54 (40)
5/8” 7/8” - 14 81 (60)
3/4” 1-1/16” - 12 114 (84)
7/8” 1-3/16” - 12 133 (98)
1” 1-5/16” - 12 160 (118)
1-1/4” 1-5/8” - 12 209 (154)
1-1/2” 1-7/8” - 12 221 (163)
2” 2-1/2” - 12 342 (252)

1030 of 1052 SPEC-40-2 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
[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.

1031 of 1052 SPEC-50-1 T870 Service Manual

1032 of 1052 SPEC-50-2 T870 Service Manual
CONVERSIONS

Decimal And Millimeter Equivalent Chart

U.S. To Metric Conversion Chart

1033 of 1052 SPEC-60-1 T870 Service Manual

1034 of 1052 SPEC-60-2 T870 Service Manual
SERVICE TOOLS REQUIRED
The following is a list of service tools required for servicing loaders.
Remote Start Tools

TOOL PART MODELS USED

DESCRIPTION COMMENT IMAGE
NUMBER ON
MEL1563 Remote Start Tool S70, S100, T110 This tool has been replaced by
S450 - S850 the new remote start tool
T450 - T870 7003031, see below. MEL1563
A770 includes: MEL1565 and
MEL1566.
MEL1565 Service Tool Harness S70, S100, T110 Used with MEL1563 to connect
S450 - S850 remote start tool to machine
T450 - T870

MEL1566 Service Tool Harness S70, S100, T110 Used with MEL1563 to connect
Communicator S450 - S850 remote start tool to PC
T450 - T870
A770
7217666 Remote Start Tool S70, S100, T110 This tool replaced the original
 KIT S450 - S850 remote start tool kit MEL1563
(Was 7003031) T450 - T870 and 7003031. Kit 7217666
 A770 includes: 7022042, 6689747,
(Was 6689779) 6689746 and 6689745.

7022042 Remote Start Tool This tool replaces remote start

 tool 6689778 and 7003030.
(Was 7003030)

(Was 6689778)
6689747 Remote Start Tool Used with 7003030 to connect
Harness remote start tool to loader

6689746 Remote Start Tool Used with 7003030 to connect

Harness Service PC to remote start tool.

6689745 BOSS Service Tool Included with 7003031 but only

Harness used on early model loaders
equipped with BOSS.

7152935 Service Tool Harness Loaders with the Used to connect the 7 pin
7 pin attachment attachment harness to remote
harness. start tool.

See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)

ST LDR-1017

1035 of 1052 SPEC-70-1 T870 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Hydraulic Tools

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1744 Hydraulic Tester S70, S100 Hydraulic tester MEL1744, MEL10003
(Flow Meter) T110 or TWX-RFIK200-S-6 can be used for
S450 - S850 hydraulic testing.
T450 - T870
A770
MEL10003 Hydraulic Tester MEL10003 and TWX-RFIK200-S-6
(Flow Meter) are no longer available, order
MEL1744.

TWX-RFIK200- Hydraulic Tester

S-6 (Flow Meter)

MEL1074 O-Ring Seal Hook

MEL1075 Adjustable Gland Includes MEL1075-1 and MEL1075-2

NUt Wrench

MEL1075-1 Standard Pins These are replaceable pins that insert No Image Available
into MEL1075 for disassembling
various cylinders
MEL1075-2 Offset Pins These are replaceable pins that insert No Image Available
into MEL1075 for disassembling
various cylinders
MEL1396-1 Universal Seal MEL1396 includes: MEL1396-1 and
Expander MEL1396-2

MEL1396-2 Piston Ring

Compressor

MEL1418 Cylinder Hone = S510 - S850

2.00 in T550 - T870
OEM6275 Cylinder Hone =
2.75 - 3.00 in
OEM6270 Cylinder Hone =
3.00 - 3.50 in
OEM6271 Cylinder Hone =
3.50 - 4.00 in
See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)
ST LDR-1017

1036 of 1052 SPEC-70-2 T870 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Hydraulic Tools (Cont’d)

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1033 Rod Seal Installation S70, S100
Tool T110
S450 - S850
T450 - T870
A770
MEL10006 Hydraulic Test Kit This test kit includes various adapters
and couplers that are used when
testing hydraulic functions. MEL10006
Includes: MEL10006-1 thru
MEL10006-7

MEL1278 Detent Tool S70, S100

T110
S450 - S850
T450 - T870
MEL1285 Detent Spring Tool S70, S100
T110
S450 - S850
T450 - T870
A770
MEL1355-2 Pressure Gauge, S450 - S850
1000 psi T450 - T870
MEL1355-3 Pressure Gauge, A770
5000 psi
MEL1723 Female Test Coupler S450 - S850 Quick coupler that connects to the
T450 - T870 hydraulic control valve on the D2
A770 valve.

MEL1173A Hydraulic Test Kit S70 This test kit includes various adapters
and couplers that are used when
testing hydraulic functions.
MEL1173A Includes: MEL1173-1 thru
MEL1173-17
TWX-4004 42mm Thinwall S450 - S850 Used to remove and install 42mm
Socket T450 - T870 couplers on the front auxiliary coupler
A770 block.

7313845 50mm Coupler S450 - S850 Used to remove and install 50mm
Was 7299828 Wrench T450 - T870 couplers on the front auxiliary coupler
A770 block.

7246786 Female Test Coupler S450 - S850 Quick coupler that connects to the
T450 - T870 hydraulic control valve on the D2
A770 valve.

See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)
ST LDR-1017

1037 of 1052 SPEC-70-3 T870 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Mainframe And Drive Tools

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1399 Seal Driver Tool S450

MEL1525 Seal Driver Tool S70

MEL1242 Power Ram S100

S450 - S850

MEL1202 Axle Bearing Service S70, S100 MEL1202 Includes:

Set S450 - S770 MEL1202-1 thru MEL1202-13

MEL1714 Axle Seal Installation S850

Tool

6675936 Bleed Tool T110 - T870 Machines with two track tension
(MEL1560) fittings.

7277225 Bleed Tool T110 - T870 Machines with one track tension
fittings.

MEL1246 Chain Link Tool S450 - S850

A770

MEL1604 Seal Driver A770

MEL1269 Chain Breaker S450 - S595

MEL1364 Chain Link Tool S450 - S595

MEL1685 Pivot Point Tapered S630 - S850

Reamer T630 - T870

MEL1734 Pivot Point Tapered S450 - S595

Reamer T450 - T595

MEL1605 Bearing Race A770

Installer

See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)
ST LDR-1017

1038 of 1052 SPEC-70-4 T870 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Mainframe And Drive Tools (Cont’d)

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1730 Bearing Race S850
Remover

MEL1731 Bearing Race S850

Installer

MEL1606 Seal Installer A770

MEL1420 Carrier Seal S510 - S595

installation Tool

MEL1612 Bearing Removal T550 - T595

Tool

MEL1562 Bearing Installation T630 - T870

Tool

MEL1431 Seal Driver Tool S630 - S770

A770

MEL1407 Seal Driver Tool S630 - S770

7313844 Cab Isolator Tool S450 - S850

T450 - T870
A770

See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)
ST LDR-1017

1039 of 1052 SPEC-70-5 T870 Service Manual

Electrical Tools

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1609 Wheel Speed S630 - S850
T630 - T870
A770

MEL1428 Sensor Tester S70,S100

T110
S450 - S850
T450 - T870
A770

MEL1567 Seat Bar Adapter S70, S100

T110
S450 - S850
T450 - T870
A770
7313846 Injector Signal Tester S450 - S850 Used to test injector signal on Bobcat
Was 7299829 T450 - T870 1.8L, 2.4L and 3.4L engines
A770

7299830 Injector Signal Tester S750 - S850 Used to test injector signal on Kubota
T750 - T870 iT4 engines.
A770

See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)
ST LDR-1017

1040 of 1052 SPEC-70-6 T870 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Engine Tools

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
7024161 Diagmaster Kit S750 - S850 Includes:
(iT4 engine only) T750 - T870 DST-i (Diagmaster Service Tool)
A770 Vehicle cable (7024272)
USB cable (7024271)
Diagmaster Diagnostic Software

MEL10630 Engine Compression S70,S100 Includes: MEL1352, MEL1433,

Test Kit T110 MEL1489, MEL1546, MEL1551,
S450 - S650, MEL1594, MEL1594,
T450 - T650 MEL10630-1 - MEL10630-11 and
MEL10630-14
MEL1655 Compression S450 - S650, Used in glow plug port for testing
Adapter T550 - T650 compression, NOT included with
MEL10630. Kubota V2607 and V3307
engines.
MEL1614 Compression S750 - S850 Used in injector port for testing
Adapter T750 - T870 compression, NOT included with
A770 MEL10630. Kubota V3300 and V3800
engines.
MEL1656 Fuel Injection Pump
Degree Restoring
Tool

MEL1657 Timing Gear Puller

Tool

7031222 Bobcat Engine T4 Bobcat Includes: Diagnostic Service Tool

Analyzer Diagnostic Engine (7031223), Vehicle Cable 6 pin
Tool Kit Applications (7031398), Vehicle Cable 14 pin
(7031356), USB Cable (7031357) 


7031370 Rear Main Seal T4 Bobcat Used for installing rear main seal
Installer Engine
Applications

7031369 Front Seal Installer T4 Bobcat Used for installing front seal
Engine
Applications

See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)
ST LDR-1017

1041 of 1052 SPEC-70-7 T870 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Engine Tools (Cont’d)

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
7031371 Valve Spring T4 Bobcat Used for compressing valve springs
Compressor Engine
Applications

MEL1733 Pivot Bushing S510 - S850 Use to install pivot bushing into
Installer T550 - T870 flywheel housing

4200 Injector Nozzle S70, S100

Tester T110
S450 - S850
T550 - T870
A770
4201 Injector Nozzle
Tester Adapter Kit

MEL1173-1 Pressure Gauge S450 - S850

10000 psi T550 - T870

MEL1637 Governor Connecting S750 - S850

Rod Tool T750 - T870
A770

MEL1667 Governor Connecting S510 - S590,

Rod Tool S750 - S850
T550, T590,
T750 - T870
MEL1660 Crankshaft S510 - S650,
Replacement Tool T550 - T650

MEL1237 Fuel Line Adapter S450 - S550

T450 - T590

MEL1724 Crankshaft Position S750 - S850 For checking crankshaft sensor on

Sensor Measuring T750 - T870 IT4 Kubota engine
Tool A770

See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)
ST LDR-1017

1042 of 1052 SPEC-70-8 T870 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Engine Tools (Cont’d)

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1725 Compression S750 - S850 Used in injector port. For checking
Adapter T750 - T870 compression on IT4 Kubota engine
A770
MEL1666 Camshaft Gear S510 - S550 Kubota V2607, V3007 and V3307
Puller T550 - T590 engines

MEL1653-1 Engine Removal Tool S450 - S850,

T450 - T870,
A770

MEL1653-2 Engine Removal Tool S750 - S850, T3 Kubota V3800 Engines

T750 - T870,
A770

MEL1653-3 Engine Removal Tool S450 - S530, Kubota V2203 and V2403 Engines
T450 and universal lift adapter.

MEL1653-4 Engine Removal Tool S550 - S590, Kubota V2607 Engines

T550 - T590

MEL1653-5 Engine Removal Tool S630, S650, Kubota V3307 Engines

T630, T650

MEL1653-6 Engine Removal Tool S750 - S850 iT4 Kubota V3800 Engines
T750 - T870,
A770

MEL1653-7 Engine Removal Tool S740 - S850 Included with MEL1653-1

Handle T740 - T870
A770

See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)
ST LDR-1017

1043 of 1052 SPEC-70-9 T870 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Engine Tools (Cont’d)

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
7111805 Mount S750 - S850 Used with MEL1653-2
(Was MEL1686) (Engine Removal T750 - T870
Tool) A770

MEL1653-8 Engine Removal Tool S740 - S850 Used with MEL1653-1

T740 - T870
A770
MEL1653-9 Engine Removal Tool S510 - S595, 2.4L Bobcat Engine Tier 4
S630, S650,
T550 - T595,
T630, T650

MEL1653-11 Engine Removal Tool S750 - S850, 3.4L Bobcat Engine Tier 4 with SCR
T750 - T870,
A770

MEL 1653-12 Engine Removal Tool S740, T740 3.4L Bobcat Engine Tier 4 without
SCR

MEL1712 Push Button Starter S450 - S850, 

Switch T450 - T870,
A770
MEL1270 Fuel Line Removal S70
Tool

MEL1271 Delivery Valve

Removal Tool

MEL1485 Injector Removal

Socket

MEL1616 Radiator Tank Test

Adapter

MEL1642 Radiator Cap Test

Adapter


See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)

ST LDR-1017

1044 of 1052 SPEC-70-10 T870 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Engine Tools (Cont’d)

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
7277084 Urea (DEF/AdBlue®) Bobcat 3.4L Includes: Filter Disassembly Tool,
Filter Service Kit Engine Filter and Equalizer.
Models Tier 4
SCR
Equipped
7299827 Compression Bobcat 3.4L Used in injector port for checking
Adapter Engine compression.
Models Tier 4

7313843 Compression Bobcat 1.8L Used in glow plug port for checking
Adapter & 2.4L compression.
Engine
Models Tier 4
7268212 Valve Lash Adjusting All Bobcat
Wrench Engine
Models

7255632 Valve Stem Seal Tool

MEL1742 Seal Installer S450 Drive motor seal installer

MEL1607 Snap Ring Installer

7332314 Turbo and Oil Sensor All Bobcat 7332314 includes: 7332313 - Oil
Block Adapter Kit Engine Sensor Block Adapter and 7332298 -
Models Turbo Oil Adapter.

See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)
ST LDR-1017

1045 of 1052 SPEC-70-11 T870 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

HVAC Tools

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1581 HVAC Recover, S450 - S850 MEL1581 is no longer available,
Recycling, T450 - T870 order MEL1735 or MEL1736
Recharging Machine A770

MEL1735 Deluxe HVAC

Recover, Recycling,
Recharging Machine

MEL1736 Standard HVAC

Recover, Recycling,
Recharging Machine

MEL1592 HVAC Refrigerant

Identification Tool

MEL1595 AC Compressor S630 - S850

Pulley Puller T630 - T870

See BobcatDealerNET.com for parts ordering information. (For EMEA dealers see the Bobcat Special Tools Catalogue
and Doosan Shop for parts ordering information.)
ST LDR-1017

1046 of 1052 SPEC-70-12 T870 Service Manual

 ALPHABETICAL INDEX

(T870) LOADER SPECIFICATIONS CONTROL PEDALS AND LINKAGES (SCPA)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-90-1
ACCESS PANEL (INSIDE) (SCPA) CONVERSIONS . . . . . . . . . . . . . . .SPEC-60-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1 CRANKSHAFT AND PISTONS . . . . .70-100-1
ACCESS PANEL (INSIDE) (SJC) . . . . 50-120-1 CYLINDER (BOB-TACH) . . . . . . . . . . .20-22-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . 70-50-1 CYLINDER (LIFT) . . . . . . . . . . . . . . . . .20-20-1
AIR CONDITIONING SYSTEM FLOW CYLINDER (TILT) . . . . . . . . . . . . . . . . .20-21-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
CYLINDER HEAD . . . . . . . . . . . . . . . .70-90-1
ALTERNATOR . . . . . . . . . . . . . . . . . . . 60-30-1
DELIVERY REPORT . . . . . . . . . . . . . . . . 1-14
ARMREST . . . . . . . . . . . . . . . . . . . . . 50-150-1
DIAGNOSTIC SERVICE CODES . . . .60-100-1
AUTOMATIC RIDE CONTROL . . . . . . 20-140-1
DIESEL EXHAUST FLUID (DEF) / ADBLUE®
BACK-UP ALARM SYSTEM . . . . . . . 60-210-1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . .70-160-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 DIESEL OXIDATION CATALYST (DOC)
BLOWER FAN . . . . . . . . . . . . . . . . . . 80-130-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-40-1
BOBCAT CONTOLERS (GATEWAY AND DOSING CONTROL UNIT (DCU) . . . .60-80-1
AUXILLIARY) . . . . . . . . . . . . . . . . . . . . 60-70-1 DRAIN MANIFOLD . . . . . . . . . . . . . . . .30-70-1
BOBCAT CONTROLLER (ACS) . . . . . . 60-71-1 DRIVE BELT . . . . . . . . . . . . . . . . . . . . .30-50-1
BOBCAT CONTROLLER (SCPA) (DRIVE) ELECTRICAL / HYDRAULIC CONTROLS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-73-1 (SCPA) . . . . . . . . . . . . . . . . . . . . . . . .60-141-1
BOBCAT CONTROLLER (SJC) (DRIVE) ELECTRICAL / HYDRAULIC CONTROLS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1 (SJC) . . . . . . . . . . . . . . . . . . . . . . . . .60-140-1
BOBCAT INTERLOCK CONTROL SYSTEM ELECTRICAL SYSTEM INFORMATION
(BICS™) . . . . . . . . . . . . . . . . . . . . . . . 60-110-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-1
BOB-TACH (HAND LEVER) . . . . . . . . 10-130-1 EMERGENCY EXIT . . . . . . . . . . . . . .10-180-1
BOB-TACH (HAND LEVER) . . . . . . . . . 50-40-1 ENGINE AIR CLEANER . . . . . . . . . . . .10-80-1
BOB-TACH (POWER) BLOCK . . . . . . 20-120-1 ENGINE COMPARTMENT TEMPERATURE
BOB-TACH (POWER) . . . . . . . . . . . . 10-131-1 SENSOR . . . . . . . . . . . . . . . . . . . . . .60-230-1
BOB-TACH (POWER) . . . . . . . . . . . . . 50-41-1 ENGINE CONTROL UNIT (ECU) . . . . .60-90-1
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1 ENGINE COOLING SYSTEM . . . . . . .10-90-1
BUCKET POSITION VALVE . . . . . . . . 20-100-1 ENGINE COOLING SYSTEM . . . . . . .70-60-1
CAB DOOR . . . . . . . . . . . . . . . . . . . . 50-140-1 ENGINE INFORMATION . . . . . . . . . . .70-10-1
CALIBRATION . . . . . . . . . . . . . . . . . . 60-160-1 ENGINE LUBRICATION SYSTEM . . .10-110-1
CAMSHAFT . . . . . . . . . . . . . . . . . . . . 70-110-1 ENGINE SPEED CONTROL (FOOT)
CHARGE PRESSURE . . . . . . . . . . . . . 30-30-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-21-1
COMPRESSOR . . . . . . . . . . . . . . . . . . 80-50-1 ENGINE SPEED CONTROL (HAND)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-20-1
CONDENSER . . . . . . . . . . . . . . . . . . . 80-60-1
EVAPORATOR / HEATER COVER . . .80-150-1
CONTROL HANDLE / LEVER (SCPA)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1 EVAPORATOR / HEATER UNIT . . . . . .80-80-1
CONTROL HANDLE / LEVER (SJC) EVAPORATOR COIL . . . . . . . . . . . . .80-110-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1 EXHAUST GAS RECIRCULATION (EGR)
CONTROL PANEL (SCPA) . . . . . . . . . 50-101-1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . .70-150-1
CONTROL PANEL (SJC) . . . . . . . . . . 50-100-1 EXPANSION VALVE . . . . . . . . . . . . . .80-100-1
CONTROL PANEL SETUP . . . . . . . . 60-180-1 FAN DUCT PANELS . . . . . . . . . . . . . .50-190-1
FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-11

1047 of 1052 INDEX-01 T870 Service Manual

FLYWHEEL AND HOUSING . . . . . . .70-140-1 LOADER STORAGE AND RETURN TO
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7 SERVICE . . . . . . . . . . . . . . . . . . . . . 10-160-1
FRONT AUXILIARY HYDRAULIC COUPLER LUBRICATING THE LOADER . . . . . 10-140-1
BLOCK . . . . . . . . . . . . . . . . . . . . . . . .20-130-1 LUBRICATION SYSTEM . . . . . . . . . . 70-70-1
FRONT HORN . . . . . . . . . . . . . . . . . .60-220-1 MAIN RELIEF VALVES . . . . . . . . . . . . 20-30-1
FUEL SYSTEM . . . . . . . . . . . . . . . . .10-100-1 MAINTENANCE CLOCK . . . . . . . . . 60-200-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . .70-80-1 MAINTENANCE SAFETY . . . . . . . . . . . . . . 1-1
FUEL TANK (AUXILIARY) . . . . . . . . . .50-81-1 OIL COOLER . . . . . . . . . . . . . . . . . . . 20-90-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . .50-80-1 OPERATOR CAB . . . . . . . . . . . . . . . . 10-30-1
GEARCASE . . . . . . . . . . . . . . . . . . . .70-120-1 OPERATOR CAB . . . . . . . . . . . . . . . . 50-20-1
HEADLINER . . . . . . . . . . . . . . . . . . . .50-180-1 OPERATOR SEAT (SUSPENSION)
HEATER COIL . . . . . . . . . . . . . . . . . .80-120-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
HEATER VALVE . . . . . . . . . . . . . . . . .80-140-1 PASSWORD SETUP (DELUXE
INSTRUMENTATION PANEL) . . . . . . 60-190-1
HYDRAULIC / HYDROSTATIC FILTERS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-70-1 PASSWORD SETUP (KEYLESS START
PANEL) . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS . . . . . . . . . . . . . SPEC-50-1 PIVOT PINS . . . . . . . . . . . . . . . . . . . 10-150-1
HYDRAULIC / HYDROSTATIC SYSTEM REAR AUXILIARY DIVERTER VALVE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
HYDRAULIC CONNECTION REAR DOOR (TAILGATE) . . . . . . . . . 50-70-1
SPECIFICATIONS . . . . . . . . . . . . . SPEC-40-1 REAR GRILLE . . . . . . . . . . . . . . . . . . 50-60-1
HYDRAULIC CONTROL VALVE (SCPA) RECEIVER / DRIER . . . . . . . . . . . . . . 80-70-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-1 REGULAR MAINTENANCE . . . . . . . . 80-20-1
HYDRAULIC CONTROL VALVE (SJC) REMOTE START TOOL (SERVICE TOOL) KIT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1 - 7217666 . . . . . . . . . . . . . . . . . . . . . . 10-61-1
HYDRAULIC FLUID RESERVOIR . . . .20-80-1 REMOTE START TOOL KIT - MEL1563
HYDRAULIC PUMP (HIGH FLOW) . . .20-61-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
HYDRAULIC PUMP . . . . . . . . . . . . . . .20-60-1 RIGHT SIDE LOWER PANEL . . . . . . 50-170-1
HYDRAULIC SYSTEM INFORMATION 20-10-1 SAFETY INSTRUCTIONS . . . . . . . . . . . . . 1-9
HYDROSTATIC DRIVE MOTOR (TWO- SEAT BAR SENSOR . . . . . . . . . . . . 60-120-1
SPEED) . . . . . . . . . . . . . . . . . . . . . . . .30-21-1 SEAT BAR . . . . . . . . . . . . . . . . . . . . . 50-10-1
HYDROSTATIC DRIVE MOTOR . . . . .30-20-1 SEAT BELT . . . . . . . . . . . . . . . . . . . . 10-190-1
HYDROSTATIC PUMP (SJC AND SCPA) SELECTIVE CATALYTIC REDUCTION (SCR)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-40-1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
HYDROSTATIC SYSTEM INFORMATION SERIAL NUMBER LOCATIONS . . . . . . . . 1-13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1
SERVICE PC (LAPTOP COMPUTER)
INSTRUMENT PANELS . . . . . . . . . . . .60-50-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
LEFT SIDE LOWER PANEL . . . . . . . .50-160-1 SERVICE SCHEDULE . . . . . . . . . . . . 10-70-1
LIFT ARM BYPASS CONTROL VALVE SERVICE TOOLS REQUIRED . . . .SPEC-70-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-50-1
STARTER . . . . . . . . . . . . . . . . . . . . . . 60-40-1
LIFT ARM SUPPORT DEVICE . . . . . .10-20-1
STEERING DRIFT COMPENSATION
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . .50-50-1 (OPERATOR MODE) . . . . . . . . . . . . 60-170-1
LIFTING AND BLOCKING THE LOADER  STEERING DRIFT COMPENSATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1 (SERVICE MODE) . . . . . . . . . . . . . . 60-171-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . .60-60-1 STOPPING THE ENGINE AND LEAVING THE
LOADER IDENTIFICATION . . . . . . . . . . . 1-15 LOADER . . . . . . . . . . . . . . . . . . . . . . 10-170-1

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SYSTEM CHARGING AND RECLAMATION 
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
TECHNICAL SERVICE GUIDE
SPECIFICATIONS . . . . . . . . . . . . . SPEC-20-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . 80-90-1
TORQUE SPECIFICATIONS FOR BOLTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
TOWING THE LOADER . . . . . . . . . . . . 10-50-1
TRACK MAINTENANCE . . . . . . . . . . . 40-30-1
TRACK UNDERCARRIAGE COMPONENTS
(ROLLER SUSPENSION) . . . . . . . . . . 40-20-1
TRACTION LOCK . . . . . . . . . . . . . . . 60-130-1
TRANSPORTING THE LOADER ON A
TRAILER . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TROUBLESHOOTING . . . . . . . . . . . . . 80-30-1
TURBOCHARGER . . . . . . . . . . . . . . . 70-130-1
TWO-SPEED / BRAKE VALVE . . . . . . 30-60-1
WINDOW (REAR) . . . . . . . . . . . . . . . 50-130-1
WINDOW (SIDE) . . . . . . . . . . . . . . . . 50-132-1
WINDOW (TOP) . . . . . . . . . . . . . . . . . 50-131-1

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