BOBCAT B730 B750 B780 Backhoe Loader Service Manual PDF DOWNLOAD

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BOBCAT B730 B750 B780 Backhoe Loader Service Manual PDF DOWNLOAD

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BOBCAT B730 B750 B780 Backhoe Loader Service Manual PDF DOWNLOAD 

Language : English
Pages : 1185
Downloadable : Yes
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TABLE OF CONTENTS:

BOBCAT B730 B750 B780 Backhoe Loader Service Manual PDF DOWNLOAD 

B730 S/N B45111001 & Above
B750 S/N B45211001 & Above
B780 S/N B45311001 & Above

MAINTENANCE SAFETY…………………………………………………………………………………………….. 3
CONTENTS……………………………………………………………………………………………………… 5
GENERAL INFORMATION……………………………………………………………………………………………. 7
MACHINE INFORMATION………………………………………………………………………………………… 9
B730 Specification……………………………………………………………………………………… 9
B750 Specification……………………………………………………………………………………… 11
B780 Specification……………………………………………………………………………………… 13
TECHNICAL PROPERTIES……………………………………………………………………………………….. 15
B730 Specifications…………………………………………………………………………………….. 15
Engine………………………………………………………………………………………………… 15
Electrical System………………………………………………………………………………………. 15
Hydraulic System……………………………………………………………………………………….. 15
Transmission…………………………………………………………………………………………… 15
Axle / Brakes………………………………………………………………………………………….. 16
Tires…………………………………………………………………………………………………. 16
Loader………………………………………………………………………………………………… 16
Backhoe……………………………………………………………………………………………….. 16
Cab / Canopy…………………………………………………………………………………………… 16
Steering………………………………………………………………………………………………. 17
Capacities…………………………………………………………………………………………….. 17
Weights……………………………………………………………………………………………….. 17
B750 Specifications…………………………………………………………………………………….. 18
Engine………………………………………………………………………………………………… 18
Electrical System………………………………………………………………………………………. 18
Hydraulic System……………………………………………………………………………………….. 18
Transmission…………………………………………………………………………………………… 18
Axle / Brakes………………………………………………………………………………………….. 19
Tires…………………………………………………………………………………………………. 19
Loader………………………………………………………………………………………………… 19
Backhoe……………………………………………………………………………………………….. 19
Cab / Canopy…………………………………………………………………………………………… 19
Steering………………………………………………………………………………………………. 19
Capacities…………………………………………………………………………………………….. 20
Weights……………………………………………………………………………………………….. 20
B780 Specifications…………………………………………………………………………………….. 21
Engine………………………………………………………………………………………………… 21
Electrical System………………………………………………………………………………………. 21
Hydraulic System……………………………………………………………………………………….. 21
Transmission…………………………………………………………………………………………… 21
Axle / Brakes………………………………………………………………………………………….. 22
Tires…………………………………………………………………………………………………. 22
Loader………………………………………………………………………………………………… 22
Backhoe……………………………………………………………………………………………….. 22
Cab / Canopy…………………………………………………………………………………………… 22
Steering………………………………………………………………………………………………. 22
Capacities…………………………………………………………………………………………….. 23
Weights……………………………………………………………………………………………….. 23
POSITION OF MACHINE………………………………………………………………………………………… 27
Loader Attachment Position………………………………………………………………………………. 27
Backhoe Attachment Position……………………………………………………………………………… 27
SAFETY INSTRUCTION…………………………………………………………………………………………. 29
General Safety Information………………………………………………………………………………. 30
Crushing And Burning Prevention………………………………………………………………………….. 31
Fire And Explosion Prevention……………………………………………………………………………. 31
Hydraulic Lines And Hoses……………………………………………………………………………….. 32
STORAGE…………………………………………………………………………………………………… 33
Preparing The Machine For Storage………………………………………………………………………… 33
Preparing The Machine For Work After A Long Period Of Storage……………………………………………….. 33
LUBRICATION AND MAINTENANCE…………………………………………………………………………………….. 35
LIFTING AND BLOCKING THE BACKHOE LOADER………………………………………………………………………. 37
Procedure……………………………………………………………………………………………… 37
APPROVED LIFT ARM SUPPORT DEVICE…………………………………………………………………………….. 39
Description……………………………………………………………………………………………. 39
TOWING THE BACKHOE LOADER…………………………………………………………………………………… 41
Procedure……………………………………………………………………………………………… 41
AXLE TOE-IN ADJUSTMENT……………………………………………………………………………………… 43
Procedure……………………………………………………………………………………………… 43
LUBRICATION……………………………………………………………………………………………….. 45
General Safety Information………………………………………………………………………………. 45
Fluids, Lubricants And Fuel……………………………………………………………………………… 46
Lubricant And Operating Materials Specifications…………………………………………………………… 48
Diesel Fuel……………………………………………………………………………………………. 49
Engine Coolant…………………………………………………………………………………………. 50
Hydraulic / Hydrostatic Fluid Chart………………………………………………………………………. 52
Brake Oil (For B730 S/N B45111001 – B45111554, B750 S/N B45211001 – B45211079 And B780 S/N B45311001 – B45311061)…. 53
Transmission Fluid……………………………………………………………………………………… 53
Front Axle Oil…………………………………………………………………………………………. 53
Rear Axle Oil………………………………………………………………………………………….. 54
Lubrication Chart (B730 And B750)………………………………………………………………………… 55
Lubrication Chart (B780)………………………………………………………………………………… 56
Diesel Engine………………………………………………………………………………………….. 57
Checking The Engine Oil Level……………………………………………………………………………. 57
Draining The Engine Oil…………………………………………………………………………………. 57
Replace The Oil Filter Element…………………………………………………………………………… 58
Adding Engine Oil………………………………………………………………………………………. 58
Cooling System…………………………………………………………………………………………. 59
Checking The Coolant Level………………………………………………………………………………. 59
Checking The Coolant Level (Cont’d)………………………………………………………………………. 60
Changing The Coolant……………………………………………………………………………………. 60
Draining Coolant……………………………………………………………………………………….. 60
Clean The Radiator And Adding Coolant…………………………………………………………………….. 61
Clean The Oil Cooler And The Radiator…………………………………………………………………….. 61
Hydraulic System……………………………………………………………………………………….. 62
Check Hydraulic Oil Level……………………………………………………………………………….. 62
To Drain Oil…………………………………………………………………………………………… 62
To Replace The Return Filter…………………………………………………………………………….. 63
Replacing The Internal Hydraulic Filter…………………………………………………………………… 63
To Clean The Suction Strainer……………………………………………………………………………. 64
Adding Hydraulic Oil……………………………………………………………………………………. 65
The Fuel System………………………………………………………………………………………… 66
Fuel Specifications…………………………………………………………………………………….. 66
Biodiesel Blend Fuel……………………………………………………………………………………. 66
Drain The Contaminant From The Fuel Filter………………………………………………………………… 67
Drain The Contaminant From The Fuel Tank………………………………………………………………….. 67
Replace The Fuel Filter Elements…………………………………………………………………………. 68
Adding Fuel……………………………………………………………………………………………. 68
Transmission System…………………………………………………………………………………….. 69
Checking Transmission Oil Level………………………………………………………………………….. 69
Draining Transmission Oil……………………………………………………………………………….. 69
Replace The Transmission Filter Elements………………………………………………………………….. 70
Add Transmission Oil……………………………………………………………………………………. 70
Front Drive Axle And Reduction Gears……………………………………………………………………… 70
To Drain Oil…………………………………………………………………………………………… 71
To Add Oil…………………………………………………………………………………………….. 71
Reduction Gears………………………………………………………………………………………… 71
To Check Reduction Gear Oil Level………………………………………………………………………… 71
To Drain Reduction Gear Oil……………………………………………………………………………… 72
Adding Reduction Gear Oil……………………………………………………………………………….. 72
Rear Axle……………………………………………………………………………………………… 72
Checking Rear Axle Oil Level…………………………………………………………………………….. 72
Cleaning The Rear Axle Breather………………………………………………………………………….. 73
Draining Rear Axle Oil………………………………………………………………………………….. 73
Adding Rear Axle Oil……………………………………………………………………………………. 73
Brake Fluid……………………………………………………………………………………………. 74
Checking Brake Fluid Reservoir Level……………………………………………………………………… 74
Adding Brake Fluid……………………………………………………………………………………… 74
Bleeding The Brake System……………………………………………………………………………….. 74
MAINTENANCE AND ADJUSTMENTS…………………………………………………………………………………. 75
Service Schedule (B730 & B750)…………………………………………………………………………… 75
Service Schedule (B780)…………………………………………………………………………………. 77
AIR CLEANER SERVICE………………………………………………………………………………………… 79
Engine Air Intake System………………………………………………………………………………… 79
Cleaning The Primary Element…………………………………………………………………………….. 80
Replacing The Air Filter Elements………………………………………………………………………… 81
Cab Air Intake Filter…………………………………………………………………………………… 81
BACKHOE BOOM / SWING LOCK…………………………………………………………………………………… 83
Engaging And Disengaging………………………………………………………………………………… 83
ENGINE ALTERNATOR / FAN BELT AND AIR CONDITIONER BELT (IF EQUIPPED)……………………………………………… 85
Maintenance Instruction…………………………………………………………………………………. 85
Replacing Fan And Alternator Belt………………………………………………………………………… 85
TIRE MAINTENANCE…………………………………………………………………………………………… 87
Type Of Tires………………………………………………………………………………………….. 87
To Replace A Wheel……………………………………………………………………………………… 87
Wheel Nut Torque Settings……………………………………………………………………………….. 87
LUBRICATING THE BACKHOE LOADER………………………………………………………………………………. 89
Lubrication Locations…………………………………………………………………………………… 89
HYDRAULIC SYSTEM………………………………………………………………………………………………. 95
HYDRAULIC / HYDROSTATIC SCHEMATICS…………………………………………………………………………… 97
HYDRAULIC SYSTEM…………………………………………………………………………………………… 103
Glossary Of Hydraulic / Hydrostatic Symbols……………………………………………………………….. 103
HYDRAULIC SYSTEM…………………………………………………………………………………………… 107
Tests And Hydraulic Pressure Test (B730)………………………………………………………………….. 107
Tests And Hydraulic Pressure Test (B750)………………………………………………………………….. 108
Tests And Hydraulic Pressure Test (B780)………………………………………………………………….. 109
Test Ports…………………………………………………………………………………………….. 110
Hydraulic Tank And Return Filter…………………………………………………………………………. 111
Fixed Displacement Tandem Pump…………………………………………………………………………… 112
Blocks………………………………………………………………………………………………… 113
ON-OFF Solenoid Valve…………………………………………………………………………………… 115
ON-OFF Pressure Reducing Valve…………………………………………………………………………… 116
Loader Control Valve……………………………………………………………………………………. 117
Unloading Valve Test……………………………………………………………………………………. 124
Steering Priority Valve…………………………………………………………………………………. 125
Backhoe Control Valve…………………………………………………………………………………… 126
Steering Pressure Test………………………………………………………………………………….. 129
Pilot Pressure Test (B750) And (B780)…………………………………………………………………….. 130
Pilot Pressure Regulation Block (B780)……………………………………………………………………. 131
Pilot Pressure Regulation Block (B750)……………………………………………………………………. 132
Priority Valve (B730 And B750)…………………………………………………………………………… 134
Priority Valve (B780)…………………………………………………………………………………… 136
RETURN LINE CHECK VALVE…………………………………………………………………………………….. 139
Removal And Installation………………………………………………………………………………… 139
HYDRAULIC CYLINDERS………………………………………………………………………………………… 141
Basic Type Cylinder Assembly…………………………………………………………………………….. 141
Nut Type Cylinder Montage……………………………………………………………………………….. 148
Loader Lift Cylinder……………………………………………………………………………………. 152
Loader Bucket (Tilt) Cylinder……………………………………………………………………………. 155
Clampshell Cylinder…………………………………………………………………………………….. 158
Backhoe Boom Cylinder…………………………………………………………………………………… 161
Backhoe Arm Cylinder……………………………………………………………………………………. 164
Backhoe Bucket Cylinder…………………………………………………………………………………. 167
Backhoe Extendible Arm Cylinder………………………………………………………………………….. 170
Backhoe Swing Cylinder………………………………………………………………………………….. 173
Backhoe Stabilizer Cylinder……………………………………………………………………………… 176
HYDRAULIC PUMP…………………………………………………………………………………………….. 179
Removal And Installation (B780)………………………………………………………………………….. 179
Removal And Installation (B730 AND B750)………………………………………………………………….. 181
BACKHOE CONTROL VALVE (B750 AND B780)………………………………………………………………………… 183
Removal And Installation………………………………………………………………………………… 183
BACKHOE CONTROL VALVE (B730)………………………………………………………………………………… 191
Removal And Installation………………………………………………………………………………… 191
BOOM CYLINDER……………………………………………………………………………………………… 197
Removal And Installation………………………………………………………………………………… 197
BUCKET CYLINDER……………………………………………………………………………………………. 199
Removal And Installation………………………………………………………………………………… 199
CLAMP CYLINDERS……………………………………………………………………………………………. 201
Removal And Installation………………………………………………………………………………… 201
CLAMSHELL CYLINDER…………………………………………………………………………………………. 203
Removal And Installation………………………………………………………………………………… 203
LIFT CYLINDERS…………………………………………………………………………………………….. 205
Removal And Installation………………………………………………………………………………… 205
STABILIZER CYLINDERS……………………………………………………………………………………….. 207
Removal And Installation………………………………………………………………………………… 207
STICK CYLINDER…………………………………………………………………………………………….. 209
Removal And Installation………………………………………………………………………………… 209
SWING CYLINDERS……………………………………………………………………………………………. 211
Removal And Installation………………………………………………………………………………… 211
TILT CYLINDERS (b750 AND b780)………………………………………………………………………………. 215
Removal And Installation………………………………………………………………………………… 215
TILT CYLINDERS (b730)………………………………………………………………………………………. 217
Removal And Installation………………………………………………………………………………… 217
BRAKE PEDAL AND BOOSTER…………………………………………………………………………………….. 219
Removal And Installation (B730 S/N B4511155 & Above) (B750 S/N B45211080 & Above) (B780 S/N B45311062 & Above)……. 219
HYDRAULIC RESERVOIR………………………………………………………………………………………… 223
Removal And Installation………………………………………………………………………………… 223
LOADER CONTROL VALVE (B750 AND B780)…………………………………………………………………………. 227
Removal And Installation………………………………………………………………………………… 227
LOADER CONTROL VALVE (B730)…………………………………………………………………………………. 231
Removal And Installation………………………………………………………………………………… 231
STEERING COLUMN AND UNIT……………………………………………………………………………………. 235
Removal And Installation………………………………………………………………………………… 235
ELECTRICAL SYSTEM……………………………………………………………………………………………… 237
ELECTRICAL SCHEMATICS………………………………………………………………………………………. 239
ELECTRICAL SYSTEM………………………………………………………………………………………….. 260
Fuses – B730 And B750…………………………………………………………………………………… 260
Relays – B730 And B750………………………………………………………………………………….. 261
Fuses – B780…………………………………………………………………………………………… 263
Relays – B780………………………………………………………………………………………….. 264
Relays – B780………………………………………………………………………………………….. 265
ELECTRICAL SYSTEM………………………………………………………………………………………….. 266
Component Location……………………………………………………………………………………… 266
Component Location – ZF In B730 And B750………………………………………………………………….. 272
Component Location – Carraro In B780……………………………………………………………………… 275
BATTERY…………………………………………………………………………………………………… 278
Removal And Installation………………………………………………………………………………… 278
FUSE……………………………………………………………………………………………………… 280
Fuse Location………………………………………………………………………………………….. 280
RELAY…………………………………………………………………………………………………….. 282
Relay Location…………………………………………………………………………………………. 282
INSTRUMENT CLUSTERS………………………………………………………………………………………… 284
Removal And Installation………………………………………………………………………………… 284
AXLES………………………………………………………………………………………………………… 290
SAFTEY INSTRUCTIONS………………………………………………………………………………………… 294
General Safety Recommendations…………………………………………………………………………… 294
FRONT AXLE – B730 AND B750………………………………………………………………………………….. 296
Description……………………………………………………………………………………………. 296
Removal And Installation………………………………………………………………………………… 297
Disassembly……………………………………………………………………………………………. 299
Reassembly…………………………………………………………………………………………….. 315
FRONT AXLE – B780………………………………………………………………………………………….. 350
Description……………………………………………………………………………………………. 350
Removal And Installation………………………………………………………………………………… 351
Tightening Torque………………………………………………………………………………………. 353
Steering Cylinder Group Disassembly………………………………………………………………………. 355
Steering Cylinder Group Assembly…………………………………………………………………………. 359
Epicyclic Reduction Gear Group Disassembly………………………………………………………………… 363
Epicyclic Reduction Gear Group Assembly…………………………………………………………………… 365
Wheel Hub Group Disassembly……………………………………………………………………………… 367
Wheel Hub Group Assembly………………………………………………………………………………… 371
Axle Beam Group Disassembly……………………………………………………………………………… 375
Axle Beam Group Assembly………………………………………………………………………………… 377
Flange Group Disassembly………………………………………………………………………………… 379
Flange Group Assembly…………………………………………………………………………………… 380
Differential Support Group Disassembly……………………………………………………………………. 382
Differential Support Group Assembly………………………………………………………………………. 384
Differential Group Disassembly…………………………………………………………………………… 390
Differential Group Assembly……………………………………………………………………………… 392
Pinion Group Disassembly………………………………………………………………………………… 393
Pinion Group Assembly…………………………………………………………………………………… 395
Toe-in / Steering Angle…………………………………………………………………………………. 400
Steering Angle Adjustment……………………………………………………………………………….. 402
Testing After Assembly………………………………………………………………………………….. 403
FRONT SHAFT – B780…………………………………………………………………………………………. 404
Removal And Installation………………………………………………………………………………… 404
REAR SHAFT – B780………………………………………………………………………………………….. 406
Removal And Installation………………………………………………………………………………… 406
FRONT SHAFT B730 AND B750…………………………………………………………………………………… 408
Removal And Installation………………………………………………………………………………… 408
REAR SHAFT – B730 AND B750………………………………………………………………………………….. 410
Removal And Installation………………………………………………………………………………… 410
SAFETY INSTRUCTIONS………………………………………………………………………………………… 412
General Safety Recommendations…………………………………………………………………………… 412
REAR AXLE – B730 AND B750…………………………………………………………………………………… 414
Preface……………………………………………………………………………………………….. 414
Lubrication And Maintenance Instructions………………………………………………………………….. 415
Service Brake – Brake Wear Measurement On The ZF- Axle MT-B 3070…………………………………………….. 417
Instructions For The Displacement Resp. Emergency Towing Of The Vehicle………………………………………. 419
Technical Data…………………………………………………………………………………………. 420
Removal And Installation………………………………………………………………………………… 422
Disassembly – Output Unit……………………………………………………………………………….. 425
Service Brake (Multi-Disc Brake)…………………………………………………………………………. 430
Differential…………………………………………………………………………………………… 433
Disassembly – Input…………………………………………………………………………………….. 438
Disassembly – Parking Brake (Multi-Disc Brake)…………………………………………………………….. 441
Disassembly – Parking Brake (Disc Brake)………………………………………………………………….. 444
Reassembly – Input……………………………………………………………………………………… 445
Reassembly – Differential……………………………………………………………………………….. 452
Assembly Service Brake (Multi-Disc Brake)…………………………………………………………………. 461
Reassembly – Output Unit………………………………………………………………………………… 469
Parking Brake Version (Multi-Disc Brake)………………………………………………………………….. 474
Reassembly of Parking Brake version (Disc Brake)…………………………………………………………… 481
Completion Of Axle……………………………………………………………………………………… 484
REAR AXLE – B780…………………………………………………………………………………………… 486
Description……………………………………………………………………………………………. 486
Removal And Installation………………………………………………………………………………… 487
Tightening Torque………………………………………………………………………………………. 490
Steering Cylinder Group Disassembly………………………………………………………………………. 493
Steering Cylinder Group Assembly…………………………………………………………………………. 497
Epicyclic Reduction Gear Group Disassembly………………………………………………………………… 502
Epicyclic Reduction Gear Group Assembly…………………………………………………………………… 504
Wheel Hub Group Disassembly……………………………………………………………………………… 506
Wheel Hub Group Assembly………………………………………………………………………………… 510
Parking Brake Group Disassembly………………………………………………………………………….. 514
Parking Brake Group Assembly…………………………………………………………………………….. 517
Parking Brake Caliper…………………………………………………………………………………… 519
Axle Beam Trumpet Group Disassembly………………………………………………………………………. 521
Axle Beam Trumpet Group Assembly…………………………………………………………………………. 524
Brake Group……………………………………………………………………………………………. 527
Brake Group Disassembly…………………………………………………………………………………. 528
Brake Group Assembly……………………………………………………………………………………. 530
Differential Support Group Disassembly……………………………………………………………………. 534
Differential Support Group Assembly………………………………………………………………………. 537
Differential Group Disassembly…………………………………………………………………………… 543
Differential Group Assembly……………………………………………………………………………… 545
Differential Lock………………………………………………………………………………………. 547
Differential Locking Group Disassembly……………………………………………………………………. 549
Differential Locking Group Assembly………………………………………………………………………. 551
Pinion Group Disassembly………………………………………………………………………………… 554
Pinion Group Assembly…………………………………………………………………………………… 557
Toe-In / Steering Angle…………………………………………………………………………………. 563
Steering Angle Adjustment……………………………………………………………………………….. 565
Testing After Assembly………………………………………………………………………………….. 566
SERVICE BRAKE……………………………………………………………………………………………… 568
Description……………………………………………………………………………………………. 568
Bleeding The Brake Circuitry…………………………………………………………………………….. 569
Test Procedure…………………………………………………………………………………………. 570
Brake System Troubleshooting…………………………………………………………………………….. 571
TRANSMISSION………………………………………………………………………………………………….. 572
MANUAL USE………………………………………………………………………………………………… 574
Maintenance……………………………………………………………………………………………. 574
Repair………………………………………………………………………………………………… 574
Agreements And Definitions………………………………………………………………………………. 574
Typographic Agreements………………………………………………………………………………….. 574
Measurements…………………………………………………………………………………………… 574
General Description…………………………………………………………………………………….. 574
Recommendations For Repair Operations…………………………………………………………………….. 575
Transmission Installation On The Machine………………………………………………………………….. 576
SAFETY INSTRUCTIONS………………………………………………………………………………………… 578
General Safety Recommendations…………………………………………………………………………… 578
TRANSMISSION – B730 AND B750………………………………………………………………………………… 580
Serial Number Plate Location…………………………………………………………………………….. 580
Preface……………………………………………………………………………………………….. 580
General……………………………………………………………………………………………….. 581
Schematics…………………………………………………………………………………………….. 582
Measuring Points For Pressure Oil And Temperature………………………………………………………….. 586
Solenoid / Gear Activation………………………………………………………………………………. 588
Hydraulic Schematic…………………………………………………………………………………….. 589
Removal And Installation………………………………………………………………………………… 590
Disassembly……………………………………………………………………………………………. 595
Reassembly…………………………………………………………………………………………….. 634
TRANSMISSION – B780………………………………………………………………………………………… 700
Component Location……………………………………………………………………………………… 700
Tightening Torque………………………………………………………………………………………. 705
Hydraulic Schematic…………………………………………………………………………………….. 708
Main Hydraulic Components……………………………………………………………………………….. 709
Kinematic Scheme……………………………………………………………………………………….. 710
Plugs And Filters Disassembly……………………………………………………………………………. 711
Removal And Installation………………………………………………………………………………… 712
Plugs And Filters Assembly………………………………………………………………………………. 721
Torque Converter And Oil Pump Disassembly…………………………………………………………………. 724
Torque Converter And Oil Pump Assembly……………………………………………………………………. 727
Hydraulic Control Valve Disassembly………………………………………………………………………. 729
Hydraulic Control Valve Assembly…………………………………………………………………………. 733
Hydraulic System Pipes Disassembly……………………………………………………………………….. 735
Hydraulic System Pipes Assembly………………………………………………………………………….. 737
Transmission Housing Disassembly…………………………………………………………………………. 738
Transmission Housing Assembly……………………………………………………………………………. 744
Shafts A – D Disassembly………………………………………………………………………………… 749
Shafts A – D Assembly…………………………………………………………………………………… 759
Axis B Disassembly……………………………………………………………………………………… 770
Axis B Assembly………………………………………………………………………………………… 778
Axis C Disassembly……………………………………………………………………………………… 786
Axis C Assembly………………………………………………………………………………………… 801
Axis E Disassembly……………………………………………………………………………………… 818
Axis E Assembly………………………………………………………………………………………… 824
ENGINE SERVICE………………………………………………………………………………………………… 834
GENERAL INFORMATION………………………………………………………………………………………… 838
Introduction…………………………………………………………………………………………… 838
Engine Views…………………………………………………………………………………………… 839
Engine Identification…………………………………………………………………………………… 840
Safety Precautions……………………………………………………………………………………… 841
Engine Lift Equipment…………………………………………………………………………………… 843
Viton Seals……………………………………………………………………………………………. 844
POWERPART Recommended Consumable Products…………………………………………………………………. 845
SPECIFICATIONS…………………………………………………………………………………………….. 848
Basic Engine Data………………………………………………………………………………………. 848
Data And Dimensions…………………………………………………………………………………….. 849
Thread Sealant…………………………………………………………………………………………. 867
Standard Torque Values………………………………………………………………………………….. 868
Specific Torque Values………………………………………………………………………………….. 869
Compression Test Data…………………………………………………………………………………… 872
CYLINDER HEAD……………………………………………………………………………………………… 874
General Description…………………………………………………………………………………….. 874
Atomiser Cover…………………………………………………………………………………………. 874
Rocker Cover…………………………………………………………………………………………… 875
Rocker Arm…………………………………………………………………………………………….. 877
Valve Tip Clearances……………………………………………………………………………………. 879
Valve Springs………………………………………………………………………………………….. 880
Removal……………………………………………………………………………………………….. 882
Installation…………………………………………………………………………………………… 884
Valve And Valve Springs…………………………………………………………………………………. 887
Valve Guides…………………………………………………………………………………………… 890
Inspection And To Correct……………………………………………………………………………….. 893
PISTON AND CONNECTING ROD ASSEMBLIES…………………………………………………………………………. 896
General Description…………………………………………………………………………………….. 896
Big End Bearing………………………………………………………………………………………… 897
Piston And Connecting Rod……………………………………………………………………………….. 899
Piston Rings…………………………………………………………………………………………… 902
Piston And Connecting Rod Assembly……………………………………………………………………….. 903
Piston And Piston Rings…………………………………………………………………………………. 905
Connecting Rod…………………………………………………………………………………………. 906
Partially Finished Small End Bush………………………………………………………………………… 907
Piston Cooling Jets…………………………………………………………………………………….. 908
CRANKSHAFT ASSEMBLY………………………………………………………………………………………… 910
General Description…………………………………………………………………………………….. 910
Crankshaft Pulley………………………………………………………………………………………. 911
Rear End Oil Seal Assembly………………………………………………………………………………. 912
To Remove And To Fit A Wear Sleeve……………………………………………………………………….. 916
Thrust Washers…………………………………………………………………………………………. 917
Main Bearings………………………………………………………………………………………….. 920
Crankshaft…………………………………………………………………………………………….. 922
Balancer Unit………………………………………………………………………………………….. 926
TIMING CASE AND DRIVE ASSEMBLY………………………………………………………………………………. 930
General Description…………………………………………………………………………………….. 930
Timing Cover…………………………………………………………………………………………… 931
Mechanical Fuel Pump Gear……………………………………………………………………………….. 933
Electronic Fuel Pump Gear……………………………………………………………………………….. 936
Idler Gear and Hub……………………………………………………………………………………… 938
Heavy Duty Idler Gear…………………………………………………………………………………… 941
Camshaft Gear………………………………………………………………………………………….. 943
Front Oil Seal…………………………………………………………………………………………. 944
Timing Case……………………………………………………………………………………………. 947
Crankshaft Gear………………………………………………………………………………………… 950
Camshaft and Tappets……………………………………………………………………………………. 951
CYLINDER BLOCK ASSEMBLY…………………………………………………………………………………….. 952
General Description…………………………………………………………………………………….. 952
Cylinder Block…………………………………………………………………………………………. 952
Cylinder Bore………………………………………………………………………………………….. 954
ENGINE TIMING……………………………………………………………………………………………… 956
General Description…………………………………………………………………………………….. 956
To Set Number 1 Piston To TDC On The Compression Stroke…………………………………………………….. 957
To Check The Timing Of The Bosch VP30 Fuel Injection Pump…………………………………………………… 958
To Check The Timing Of The Bosch EPVE Fuel Injection Pump…………………………………………………… 959
To Adjust The Timing Of The Bosch EPVE Fuel Injection Pump………………………………………………….. 960
To Check The Timing Of The Delphi DP210 Fuel Injection Pump…………………………………………………. 962
To Check The Valve Timing……………………………………………………………………………….. 963
ASPERATION SYSTEM………………………………………………………………………………………….. 964
General Description…………………………………………………………………………………….. 964
Exhaust Elbow………………………………………………………………………………………….. 965
Turbocharger Side Mount…………………………………………………………………………………. 966
Turbocharger Faults…………………………………………………………………………………….. 969
Open Engine Breather……………………………………………………………………………………. 971
Natural Aspirated Engine Breather………………………………………………………………………… 972
Closed Engine Breather………………………………………………………………………………….. 973
LUBRICATION SYSTEM…………………………………………………………………………………………. 974
General Description…………………………………………………………………………………….. 974
Lubrication System Flow Diagram………………………………………………………………………….. 975
Canister Type Oil Filter………………………………………………………………………………… 976
Element Type Oil Filter…………………………………………………………………………………. 977
Filter Head……………………………………………………………………………………………. 978
Sump………………………………………………………………………………………………….. 979
Dipstick Tube………………………………………………………………………………………….. 981
Oil Strainer And Suction Pipe……………………………………………………………………………. 982
Lubricating Oil Pump Assembly……………………………………………………………………………. 983
Relief Valve…………………………………………………………………………………………… 985
FUEL SYSTEM……………………………………………………………………………………………….. 988
General Description…………………………………………………………………………………….. 988
Cold Start Advance Unit (KSB)……………………………………………………………………………. 990
Typical Fuel System…………………………………………………………………………………….. 991
Fuel Filter Assembly……………………………………………………………………………………. 992
Atomizers……………………………………………………………………………………………… 993
Fuel Lift Pump And Filter Assembly……………………………………………………………………….. 996
Removing Air From The Fuel System………………………………………………………………………… 998
Bosch VP30 Fuel Injection Pump…………………………………………………………………………… 999
Bosch EVPE Fuel Injection Pump……………………………………………………………………………1004
Delphi DP210 Fuel Injection Pump………………………………………………………………………….1007
COOLING SYSTEM……………………………………………………………………………………………..1012
General Description……………………………………………………………………………………..1012
Coolant Flow Diagram…………………………………………………………………………………….1013
Thermostat……………………………………………………………………………………………..1014
Coolant Pump……………………………………………………………………………………………1017
Fan……………………………………………………………………………………………………1021
Fan Drive………………………………………………………………………………………………1021
Lubricating Oil Cooler…………………………………………………………………………………..1022
Coolant Bypass Pipe……………………………………………………………………………………..1024
Oil Cooler / Radiator Removal And Installation B780…………………………………………………………1025
Oil Cooler / Radiator Removal And Installation B730 And B750…………………………………………………1027
FLYWHEEL AND HOUSING………………………………………………………………………………………..1030
General Description……………………………………………………………………………………..1030
Flywheel……………………………………………………………………………………………….1030
Ring Gear………………………………………………………………………………………………1031
Flywheel Housing………………………………………………………………………………………..1032
ELECTRICAL SYSTEM…………………………………………………………………………………………..1034
General Description……………………………………………………………………………………..1034
Alternator……………………………………………………………………………………………..1034
Starting Aid (Glow Plug)…………………………………………………………………………………1040
Electrical Components……………………………………………………………………………………1042
Engine Control Module (ECM)………………………………………………………………………………1044
Voltage Load Protection Module……………………………………………………………………………1046
Programming A New ECM……………………………………………………………………………………1047
Speed And Timing Sensor………………………………………………………………………………….1048
Pressure Sensor…………………………………………………………………………………………1049
Temperature Sensor………………………………………………………………………………………1051
Wiring Harness………………………………………………………………………………………….1053
AUXILIARY EQUIPMENT…………………………………………………………………………………………1060
Power Steering Pump……………………………………………………………………………………..1060
Adaptor For A Hydraulic Pump Or A Steering Pump…………………………………………………………….1060
Exhauster………………………………………………………………………………………………1063
SPECIAL TOOLS………………………………………………………………………………………………1064
List Of Special Tools……………………………………………………………………………………1064
REAR HAND THROTTLE LEVER…………………………………………………………………………………….1068
Cable Adjustment Procedure……………………………………………………………………………….1068
ACCELERATOR PEDAL…………………………………………………………………………………………..1070
Removal And Installation…………………………………………………………………………………1070
Cable Adjustment Procedure……………………………………………………………………………….1072
EXHAUST……………………………………………………………………………………………………1074
Removal And Installation…………………………………………………………………………………1074
AIR FILTER…………………………………………………………………………………………………1076
Housing Removal And Installation………………………………………………………………………….1076
ENGINE B780………………………………………………………………………………………………..1078
Removal And Installation…………………………………………………………………………………1078
ENGINE B730 AND B750………………………………………………………………………………………..1084
Removal And Installation…………………………………………………………………………………1084
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)…………………………………………………………………..1092
HVAC UNIT………………………………………………………………………………………………….1094
Removal………………………………………………………………………………………………..1094
Installation……………………………………………………………………………………………1100
MAIN FRAME…………………………………………………………………………………………………….1114
BACKHOE BOOM / SWING LOCK……………………………………………………………………………………1116
Removal And Installation…………………………………………………………………………………1116
BACKHOE BUCKET TEETH………………………………………………………………………………………..1118
Removal And Installation…………………………………………………………………………………1118
LOADER BUCKET TEETH…………………………………………………………………………………………1120
Removal And Installation…………………………………………………………………………………1120
BOOM………………………………………………………………………………………………………1122
Removal And Installation…………………………………………………………………………………1122
CAB (B750 AND B780)…………………………………………………………………………………………1124
Removal And Installation…………………………………………………………………………………1124
CAB (B730)…………………………………………………………………………………………………1136
Removal And Installation…………………………………………………………………………………1136
COUNTERWEIGHT………………………………………………………………………………………………1148
Removal And Installation…………………………………………………………………………………1148
ENGINE COVER……………………………………………………………………………………………….1150
Removal And Installation…………………………………………………………………………………1150
ENGINE SIDE COVERS………………………………………………………………………………………….1152
Removal And Installation…………………………………………………………………………………1152
FRONT MUDGUARD (B780)……………………………………………………………………………………….1154
Removal And Installation…………………………………………………………………………………1154
FRONT MUDGUARD (B730 AND B750)……………………………………………………………………………….1156
Removal And Installation…………………………………………………………………………………1156
PARKING LEVER………………………………………………………………………………………………1158
Removal And Installation…………………………………………………………………………………1158
FUEL TANK………………………………………………………………………………………………….1160
Removal And Installation…………………………………………………………………………………1160
GRILL FRAME………………………………………………………………………………………………..1162
Removal And Installation…………………………………………………………………………………1162
GRILLE…………………………………………………………………………………………………….1164
Removal And Installation…………………………………………………………………………………1164
KINGPOST…………………………………………………………………………………………………..1166
Removal And Installation…………………………………………………………………………………1166
SIDE SHIFT…………………………………………………………………………………………………1170
Removal And Installation…………………………………………………………………………………1170
STICK……………………………………………………………………………………………………..1172
Removal And Installation…………………………………………………………………………………1172
FRONT CONSOLE………………………………………………………………………………………………1176
Removal And Installation…………………………………………………………………………………1176
STABILIZER WEAR PADS………………………………………………………………………………………..1180
Adjustment……………………………………………………………………………………………..1180
ALPHABETICAL INDEX……………………………………………………………………………………………..1182

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