Bobcat A770 All-Wheel Steer Loader Service Manual SN ASRW11001 & Above – PDF DOWNLOAD

Description

Bobcat A770 All-Wheel Steer Loader Service Manual SN ASRW11001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat A770 All-Wheel Steer Loader Service Manual SN ASRW11001 & Above – PDF DOWNLOAD

Language : English
Pages : 802
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat A770 All-Wheel Steer Loader Service Manual SN ASRW11001 & Above – PDF DOWNLOAD

FOREWORD:

This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

SAFETY INSTRUCTIONS:

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:

TABLE OF CONTENTS:

Bobcat A770 All-Wheel Steer Loader Service Manual SN ASRW11001 & Above – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 12
FIRE PREVENTION 14
Maintenance 14
Operation 14
Electrical 14
Hydraulic System 14
Fueling 14
Starting 14
Spark Arrester Exhaust System 14
Welding And Grinding 15
Fire Extinguishers 15
SERIAL NUMBER LOCATIONS 16
Loader Serial Number 16
Engine Serial Number 16
DELIVERY REPORT 17
LOADER IDENTIFICATION 18
SAFETY & MAINTENANCE 19
LIFTING AND BLOCKING THE LOADER 23
Procedure 23
LIFT ARM SUPPORT DEVICE 25
Installing 25
Removing 26
OPERATOR CAB 27
Description 27
Raising 28
Lowering 29
Cab Door Sensor 30
Special Applications Kit 30
Special Applications Kit Inspection And Maintenance 30
Forestry Door And Window Kit 31
Forestry Door And Window Kit Inspection And Maintenance 31
TRANSPORTING LOADER ON A TRAILER 33
Loading And Unloading 33
Fastening 33
TOWING THE LOADER 35
Procedure 35
REMOTE START TOOL KIT-MEL1563 37
Remote Start Tool – MEL1563 37
Service Tool Harness Communicator – MEL1566 39
Remote Start Procedure 39
REMOTE START TOOL (SERVICE TOOL) KIT – 7003031 43
Description 43
Remote Start Tool (Service Tool) – 7003030 44
Loader Service Tool Harness – 6689747 45
Computer Service Tool Harness – 6689746 46
Remote Start Procedure 47
SERVICE SCHEDULE 51
Chart 51
AIR CLEANER SERVICE 53
Replacing Filter Elements 53
ENGINE COOLING SYSTEM 55
Maintenance Platform 55
Cleaning 55
Checking Level 57
Removing And Replacing Coolant 57
FUEL SYSTEM 59
Fuel Specifications 59
Biodiesel Blend Fuel 59
Filling The Fuel Tank 60
Fuel Filter 61
Removing Air From The Fuel System 61
ENGINE LUBRICATION SYSTEM 63
Checking And Adding Engine Oil 63
Engine Oil Chart 63
Removing And Replacing Oil And Filter 64
HYDRAULIC / HYDROSTATIC SYSTEM 65
Checking And Adding Fluid 65
Hydraulic / Hydrostatic Fluid Chart 65
Removing And Replacing Hydraulic Fluid 66
Removing And Replacing Hydraulic / Hydrostatic Filter 68
Removing And Replacing Steering Filter 69
Removing And Replacing Hydraulic Charge Filter 70
Breather Cap 71
FINAL DRIVE TRANSMISSION (CHAINCASE) 73
Checking And Adding Oil 73
Removing And Replacing Oil 73
BOB-TACH (HAND LEVER) 75
Inspection And Maintenance 75
BOB-TACH (POWER) 77
Inspection And Maintenance 77
LUBRICATING THE LOADER 79
Lubrication Locations 79
TIRE MAINTENANCE 83
Wheel Nuts 83
Rotating 83
Mounting 83
SPARK ARRESTER MUFFLER 85
Cleaning Procedure 85
PIVOT PINS 87
Inspection And Maintenance 87
LOADER STORAGE AND RETURN TO SERVICE 89
Storage 89
Return To Service 89
STOPPING THE ENGINE AND LEAVING THE LOADER 91
Procedure 91
EMERGENCY EXIT 93
External Access 93
Rear Window 93
Front Door 93
SEAT BELT 95
Inspection And Maintenance 95
HYDRAULIC SYSTEM 97
HYDRAULIC / HYDROSTATIC SCHEMATICS 101
HYDRAULIC SYSTEM INFORMATION 105
Glossary Of Hydraulic / Hydrostatic Symbols 105
Troubleshooting 109
CYLINDER (LIFT) 111
Testing 111
Removal And Installation 112
Parts Identification 116
Disassembly 117
Assembly 119
CYLINDER (TILT) 123
Testing 123
Removal And Installation 124
Base End Pivot Pin Removal And Installation 125
Parts Identification 126
Disassembly 127
Assembly 129
CYLINDER (BOB-TACH) 133
Testing 133
Removal And Installation 134
Parts Identification 135
Disassembly 136
Assembly 138
CYLINDER (STEERING) 141
Testing 141
Removal And Installation (Front) 143
Removal And Installation (Rear) 146
Parts Identification 149
Disassembly 150
Assembly 151
MAIN RELIEF VALVE 155
Description 155
Testing 156
Adjusting 158
Removal And Installation 158
HYDRAULIC CONTROL VALVE 161
Description 161
Removal And Installation 161
Actuator Removal And Installation (In Loader) 165
Actuator Removal And Installation (Out Of Loader) 167
Identification Chart 170
Mount Bracket Removal And Installation 171
Lift Load Check Valve Removal And Installation 171
Load Check Valve Removal And Installation (Tilt And Auxiliary) 172
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 173
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 173
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 174
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 174
Port Relief Valve Removal And Installation (Auxiliary) 175
Plug Removal And Installation 176
End Cap Block Removal And Installation 177
Lift Spool Removal And Installation 177
Tilt Spool Removal And Installation 181
Auxiliary Spool Removal And Installation 184
Auxiliary Solenoid Removal And Installation 185
Solenoid Removal And Installation 186
Lock Valve Removal And Installation 187
Lift Arm Bypass Orifice Inspection 188
Main Relief Valve Removal And Installation 188
Check Valve Removal And Installation 189
LIFT ARM BYPASS CONTROL VALVE 191
Description 191
Testing 191
Removal And Installation 192
Bracket Removal And Installation 193
Disassembly And Assembly 193
HYDRAULIC PUMP 195
Description 195
Pump Test At Quick Couplers 196
Direct Pump Test (Standard Section) 198
Direct Pump Test (Charge Section) 200
Direct Pump Test (Steering Section) 202
Removal And Installation 204
Hydraulic Pump Startup 206
Parts Identification 207
Disassembly And Assembly 208
HYDRAULIC PUMP (HIGH FLOW) 209
Description 209
Pump Test At Quick Couplers 210
Direct Pump Test (Standard Section) 212
Direct Pump Test (Charge Section) 213
Direct Pump Test (High Flow Section) 215
High Flow Relief Valve Adjustment 217
High Flow Relief Valve Removal And Installation 218
Direct Pump Test (Steering Section) 219
Solenoid Removal And Installation 221
Removal And Installation 222
Hydraulic Pump Startup 224
Parts Identification 225
Disassembly And Assembly 226
HYDRAULIC / HYDROSTATIC FILTERS 227
Description 227
Housing Removal And Installation 228
HYDRAULIC FLUID RESERVOIR 231
Description 231
Removal And Installation 231
Hydraulic Fluid Screen 232
OIL COOLER 233
Description 233
Removal And Installation 233
BUCKET POSITION VALVE 235
Description 235
Solenoid Removal And Installation 235
Solenoid Testing 236
Removal And Installation 236
Disassembly And Assembly 239
REAR AUXILIARY DIVERTER VALVE 241
Description 241
Solenoid Testing 241
Removal And Installation 242
Disassembly And Assembly 243
BOB-TACH (POWER) BLOCK 249
Description 249
Removal And Installation 249
Disassembly And Assembly 251
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 255
Description 255
Removal And Installation 255
Disassembly And Assembly 255
HYDROSTATIC SYSTEM 257
HYDROSTATIC SYSTEM INFORMATION 259
Troubleshooting 259
Description 260
HYDROSTATIC MOTOR (TWO-SPEED) 261
Description 261
Removal And Installation 261
Parts Identification 264
Disassembly 265
Assembly 271
HYDROSTATIC MOTOR CARRIER (SJC) 277
Description 277
Removal And Installation 278
Parts Identification 280
Disassembly 281
Assembly 284
CHARGE PRESSURE 287
Description 287
Testing 288
Sender Removal And Installation 289
Adjusting 290
HYDROSTATIC PUMP (SJC) 291
Description 291
Hydraulic Controller Removal And Installation 292
Removal And Installation 294
Hydrostatic Pump Start Up 296
Parts Identification 297
High Pressure Relief And Bypass Valve 298
Charge Relief Valve 299
Disassembly 300
Inspection 309
Assembly 313
Mechanical Neutral Adjustment 323
Hydraulic Controller Neutral Adjustment 326
DRIVE BELT 329
Belt Adjustment 329
Belt Replacement 329
Stop Adjustment 331
Tensioner Pulley Removal And Installation 332
Tensioner Pulley Disassembly And Assembly 333
TWO-SPEED / BRAKE VALVE 335
Description 335
Valve Block Removal And Installation 336
Valve Block Disassembly And Assembly 338
DRAIN MANIFOLD 341
Description 341
Drain Manifold Removal And Installation 341
DRIVE SYSTEM 343
BRAKE 345
Description 345
STEERING BLOCK 347
Description 347
Identification 348
Removal And Installation 350
Disassembly And Assembly 351
DRIVE COMPONENTS 359
Description 359
Axle Seal Removal And Installation 360
Axle, Sprocket And Bearings Removal And Installation 362
Chain Removal And Installation 367
CHAINCASE 369
Description 369
Front Cover Removal And Installation 369
Center Cover Removal And Installation 370
Rear Cover Removal And Installation 371
HUB 373
Description 373
Removal 373
Installation 376
Disassembly 380
Assembly 383
MAINFRAME 387
SEAT BAR 391
Description 391
Removal And Installation 391
Disassembly And Assembly 392
Compression Spring Disassembly And Assembly 393
OPERATOR CAB 395
Gas Spring Removal And Installation 395
Gas Spring Bracket Disassembly And Assembly 396
Removal And Installation 396
OPERATOR SEAT (SUSPENSION) 399
Removal And Installation 399
Slide Rail Removal And Installation 399
Seat Belt Removal And Installation 400
Lower Cushion Removal 400
Lower Cushion Installation 401
Back Cushion Removal And Installation 401
Shock Removal And Installation 402
3-Point Seat Belt Removal And Installation 402
BOB-TACH (HAND LEVER) 405
Description 405
Removal And Installation 405
Lever And Wedge Disassembly And Assembly 407
Pivot Pin Bushing And Seal Removal And Installation 409
BOB-TACH (POWER) 411
Description 411
Removal And Installation 411
Lever And Wedge Disassembly And Assembly 414
Pivot Pin Bushing And Seal Removal And Installation 415
LIFT ARMS 417
Stabilizer Bar Removal And Installation 417
Link Removal And Installation 418
Removal And Installation 419
REAR GRILLE 423
Removing 423
Installing 423
REAR DOOR (TAILGATE) 425
Removal And Installation 425
Striker Removal And Installation 426
Striker Adjusting 426
Latch Removal And Installation 427
FUEL TANK 429
Removal And Installation 429
Fuel Level Sender Removal And Installation 431
Fuel Fill Screen Removal And Installation 432
FUEL TANK (AUXILIARY) 433
Removal And Installation 433
FLOOR PAN 435
Floor Pan Removal And Installation 435
CONTROL PANEL 437
Description 437
Removal And Installation 437
JOYSTICK CONTROL 439
Description 439
Joystick Testing 439
Joystick Removal And Installation 440
ACCESS PANEL (INSIDE) (SJC) 441
Removal And Installation (Left) 441
Removal And Installation (Right) 441
WINDOW (REAR) 443
Removal And Installation 443
Disassembly And Assembly 443
WINDOW (TOP) 445
Removal And Installation 445
WINDOW (SIDE) 447
Removal And Installation 447
CAB DOOR 449
Description 449
Removal And Installation 449
Disassembly And Assembly 450
Aligning 451
Adjusting 452
Checking Operation 452
ARMREST 453
Description 453
Removal And Installation 454
Disassembly And Assembly 455
LEFT SIDE LOWER PANEL 457
Removal And Installation 457
Disassembly And Assembly 459
RIGHT SIDE LOWER PANEL 461
Removal And Installation 461
Disassembly And Assembly 462
HEADLINER 465
Removal And Installation 465
ELECTRICAL SYSTEM & ANALYSIS 467
ELECTRICAL SCHEMATICS 471
ELECTRICAL SYSTEM INFORMATION 489
Glossary Of Electrical Symbols 489
Cab Harness Connectors 492
Mainframe Harness Connectors 493
Description 494
Troubleshooting 495
Fuse And Relay Location / Identification 496
Solenoid Testing 498
BATTERY 499
Removal And Installation 499
Servicing 500
Using A Booster Battery (Jump Starting) 501
ALTERNATOR 503
Belt Adjustment 503
Belt Replacement 503
Charging System Inspection 504
Alternator Voltage Testing 505
Low Voltage Testing 505
High Voltage Testing 506
Removal And Installation 507
Parts Identification 508
STARTER 509
Testing 509
Removal And Installation 509
Parts Identification 510
INSTRUMENT PANELS 511
Left Panel 511
Display Screen 513
Right Panel (Standard Key Panel) 513
Right Panel (Keyless Start Panel) 514
Right Panel (Deluxe Instrumentation Panel) 515
Left Switch Panel 517
Right Switch Panel 517
Left Side Lower Panel 518
Right Side Lower Panel 518
Left Panel Removal And Installation 519
Right Panel Removal And Installation 519
Key Switch Disassembly And Assembly 520
Alarm Disassembly And Assembly 520
Left Switch Panel Removal And Installation 521
Right Switch Panel Removal And Installation 521
LIGHTS 523
Front Removal And Installation 523
Rear Removal And Installation 524
Cab Light Removal And Installation 524
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) 525
Description 525
Connector Identification 526
Removal And Installation 532
BOBCAT CONTROLLER (ACS) 533
Description 533
Connector And Wire Identification 534
Removal And Installation 535
BOBCAT CONTROLLER (DRIVE PLUS) 537
Description 537
Connector Identification 538
Removal And Installation 540
SPEED SENSORS 541
Description 541
Testing 541
Removal And Installation 543
DIAGNOSTIC SERVICE CODES 545
Viewing Service Codes 545
Service Codes List 546
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 551
Description 551
Inspecting The BICS™ (Engine STOPPED – Key ON) 552
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 552
Inspecting The Seat Bar Sensor (Engine RUNNING) 552
Inspecting The Traction Lock (Engine RUNNING) 552
Inspecting The Lift Arm Bypass Control 552
Inspecting Deactivation Of Lift And Tilt Functions (SJC) 552
Troubleshooting 553
SEAT BAR SENSOR 555
Description 555
Troubleshooting 555
Testing 556
Removal And Installation 557
Bobcat Interlock Control System (BICS™) Circuit Test 560
TRACTION LOCK 563
Description 563
Troubleshooting 564
Inspecting 565
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 567
Identification Chart 567
Description 568
Identification Chart ACD Group 0 569
Identification Chart ACD Group 1 570
Identification Chart ACD Group 2 571
Identification Chart ACD Group 3 572
SERVICE PC (LAPTOP COMPUTER) 573
Connecting Remote Start Tool 573
Connecting Remote Start Tool (Service Tool) 573
CALIBRATION 575
Description 575
Actuator Testing 575
Lift And Tilt Calibration 578
Hydrostatic Pump Calibration 580
STEERING DRIFT COMPENSATION 585
Description 585
Operation 585
FLYWHEEL RPM SENSOR 587
Description 587
Removal 587
Installation 587
CONTROL PANEL SETUP 589
Right Panel Setup (Deluxe Instrumentation Panel) 589
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 591
Password Description 591
Changing The Owner Password 591
Changing The User Passwords 592
Password Lockout Feature 592
PASSWORD SETUP (KEYLESS START PANEL) 593
Password Description 593
Changing The Owner Password 593
Password Lockout Feature 593
MAINTENANCE CLOCK 595
Description 595
Setup 596
Reset 599
BACK-UP ALARM SYSTEM 601
Description 601
Inspecting 601
Troubleshooting 602
Alarm Removal And Installation 603
FRONT HORN 605
Description 605
Inspecting 605
Front Horn Removal And Installation 605
Troubleshooting 606
ENGINE SERVICE 607
ENGINE INFORMATION 611
Description 611
Specifications 612
Troubleshooting 615
Engine Removal And Installation 617
Engine Mount Replacement 624
Compression – Checking 625
ENGINE SPEED CONTROL (HAND) 627
Removal And Installation 627
Disassembly And Assembly 627
Cable Removal And Installation 628
ENGINE SPEED CONTROL (FOOT) 629
Removal And Installation 629
Disassembly And Assembly 630
MUFFLER 633
Removal And Installation 633
AIR CLEANER 635
Housing Removal And Installation 635
ENGINE COOLING SYSTEM 637
Radiator Removal And Installation 637
Hydraulic Fan Description 639
Fan Duct Removal And Installation 639
Hydraulic Fan Motor Assembly Removal And Installation 640
Hydraulic Fan Motor Removal And Installation 640
Hydraulic Fan Motor Disassembly And Assembly 642
Blower Housing Removal And Installation 643
Water Pump Removal And Installation 644
Water Pump Disassembly And Assembly 644
Thermostat Housing Removal And Installation 645
Thermostat – Checking 645
LUBRICATION SYSTEM 647
Oil Pan Removal And Installation 647
Oil Pump Removal And Installation 648
Oil Pump Inspection 648
Oil Filter Cooler Removal And Installation 650
Engine Oil Pressure – Testing 651
FUEL SYSTEM 653
Fuel Shutoff Solenoid – Checking 653
Fuel Shutoff Solenoid Removal And Installation 653
Fuel Injection Pump Assembly Removal 654
Fuel Injection Pump Assembly Installation 657
Governor Housing Disassembly And Assembly 660
Governor Disassembly And Assembly 662
Fuel Camshaft Removal And Installation 664
Fuel Injection Pump Removal 666
Fuel Injection Pump Installation 669
Injection Pump – Timing 672
Fuel Injector Removal And Installation 675
Fuel Injector Nozzle Pressure – Checking 676
Nozzle Spraying Condition 677
Valve Seat Tightness 677
CYLINDER HEAD 679
Intake Air Heater – Testing 679
Intake Air Heater Removal And Installation 679
Valve Clearance Adjustment 680
Valve Timing – Checking 682
Cylinder Head Removal And Installation 683
Cylinder Head Disassembly And Assembly 686
Cylinder Head – Servicing 686
Cylinder Head Top Clearance 687
Valve Guide – Checking 688
Reconditioning The Valve And Valve Seat 690
Valve Spring 692
Valve Tappets 693
Rocker Arm And Shaft – Checking 694
Push Rod Alignment – Checking 694
CRANKSHAFT AND PISTONS 695
Piston And Connecting Rod Removal And Installation 695
Piston And Connecting Rod – Servicing 697
Cylinder Bore – Checking 701
Connecting Rod Alignment 702
Crankshaft Gear Removal And Installation 702
Crankshaft And Bearings Removal 703
Crankshaft And Bearings Installation 705
Crankshaft And Bearings – Servicing 707
CAMSHAFT AND TIMING GEARS 713
Timing Gearcase Cover Removal And Installation 713
Timing Gears Backlash – Checking 714
Idler Gear And Camshaft Removal And Installation 714
Camshaft – Servicing 715
Idler Gear And Shaft – Servicing 717
TURBOCHARGER 719
Description 719
Testing 719
Removal And Installation 721
FLYWHEEL AND HOUSING 723
Flywheel Removal And Installation 723
Ring Gear Removal And Installation 723
Housing Removal And Installation 724
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 725
AIR CONDITIONING SYSTEM FLOW 727
Description 727
Chart 728
Components 729
Safety Equipment 732
REGULAR MAINTENANCE 733
Filters 733
Compressor Drive Belt Adjustment 734
Compressor Drive Belt Replacement 734
Condenser 734
Air Conditioning Lubrication 734
Air Conditioning Service Chart 735
Evaporator / Heater Coil 736
TROUBLESHOOTING 737
Blower Motor Does Not Operate 737
Blower Motor Operates Normally, But Air Flow Is Insufficient 737
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 737
The Compressor Does Not Operate At All, Or Operates Improperly 737
Gauge Pressure Related Troubleshooting 738
Troubleshooting Tree 740
Temperature / Pressure Chart 743
Poor A/C Performance 745
HVAC Repair And Leaks 746
Electrical System 747
Engine Coolant Bypassing The Heater Valve 753
Heater Valve Not Opening Or Closing 754
SYSTEM CHARGING AND RECLAMATION 755
Refrigerant Identification 755
Reclamation And Charging With Recovery / Charging Unit 756
COMPRESSOR 759
Removal And Installation 759
Oil 761
Oil Check 762
CONDENSER 763
Removal And Installation 763
RECEIVER / DRIER 765
Receiver / Drier Removal And Installation 765
Pressure Relief Valve Removal And Installation 766
Pressure Switch Removal And Installation 767
Schrader® Valve Removal And Installation 768
EVAPORATOR / HEATER UNIT 769
Removal And Installation 769
THERMOSTAT 771
Description 771
Removal And Installation 772
EXPANSION VALVE 773
Removal And Installation 773
EVAPORATOR COIL 775
Removal And Installation 775
HEATER COIL 777
Removal And Installation 777
BLOWER FAN 779
Removal And Installation 779
Disassembly And Assembly 779
HEATER VALVE 783
Removal And Installation 783
SPECIFICATIONS 785
(A770) LOADER SPECIFICATIONS 787
Machine Dimensions 787
Performance 788
Engine 788
Drive System 789
Controls 789
Hydraulic System 790
Electrical System 791
Capacities 791
Tires 791
TORQUE SPECIFICATIONS FOR BOLTS 793
Torque For General SAE Bolts 793
Torque For General Metric Bolts 794
HYDRAULIC CONNECTION SPECIFICATIONS 795
Straight Thread O-ring Fitting 795
Flare Fitting 796
Tubelines And Hoses 796
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 797
Specifications 797
CONVERSIONS 799
Decimal And Millimeter Equivalent Chart 799
U S To Metric Conversion Chart 799
ALPHABETICAL INDEX 801

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• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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