BOBCAT B780 Backhoe Loader Service Manual SN B4U311001 PDF DOWNLOAD

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BOBCAT B780 Backhoe Loader Service Manual SN B4U311001 PDF DOWNLOAD

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BOBCAT B780 Backhoe Loader Service Manual SN B4U311001 PDF DOWNLOAD

Language : English
Pages : 828
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

BOBCAT B780 Backhoe Loader Service Manual SN B4U311001 PDF DOWNLOAD

MAINTENANCE SAFETY…………………………………………………….. 3
CONTENTS……………………………………………………………… 5
GENERAL INFORMATION……………………………………………………. 7
MACHINE INFORMATION………………………………………………… 9
TECHNICAL PROPERTIES……………………………………………….. 11
Engine………………………………………………………… 11
Electrical System………………………………………………. 11
Hydraulic System……………………………………………….. 11
Transmission…………………………………………………… 11
Axles / Brakes…………………………………………………. 12
Tires…………………………………………………………. 12
Loader………………………………………………………… 12
Backhoe……………………………………………………….. 12
Cab / Canopy…………………………………………………… 12
Steering………………………………………………………. 13
Capacities…………………………………………………….. 13
Weights……………………………………………………….. 13
MACHINE COMPONENTS…………………………………………………. 15
Standard………………………………………………………. 16
Optional………………………………………………………. 16
Optional Attachments……………………………………………. 16
POSITION OF MACHINE………………………………………………… 17
Loader Attachment Position………………………………………. 17
Backhoe Attachment Position……………………………………… 17
SAFETY INSTRUCTIONS………………………………………………… 19
General Safety Information………………………………………. 20
Crushing And Burning Prevention………………………………….. 21
Fire And Explosion Prevention……………………………………. 21
Hydraulic Lines And Hoses……………………………………….. 22
STORAGE…………………………………………………………… 23
Preparing The Machine For Storage………………………………… 23
Preparing The Machine For Work After A Long Period Of Storage……….. 23
LUBRICATION AND MAINTENANCE…………………………………………….. 25
LIFTING AND BLOCKING THE BACKHOE LOADER………………………………. 29
Procedure……………………………………………………… 29
APPROVED LIFT ARM SUPPORT DEVICE…………………………………….. 31
Description……………………………………………………. 31
Installing The Approved Lift Arm Support Device……………………. 31
Placing The Approved Lift Arm Support Device In The Storage Position…. 32
TOWING THE BACKHOE LOADER…………………………………………… 33
Procedure……………………………………………………… 33
AXLE TOE-IN ADJUSTMENT……………………………………………… 35
Procedure……………………………………………………… 35
LUBRICATION……………………………………………………….. 37
General Safety Information………………………………………. 37
Fluids, Lubricants And Fuel……………………………………… 38
Lubricant And Operating Materials Specifications…………………… 39
Lubrication Chart………………………………………………. 42
Diesel Engine………………………………………………….. 45
Checking The Engine Oil Level……………………………………. 45
Draining The Engine Oil…………………………………………. 45
Replacing The Engine Oil Filter Element…………………………… 46
Adding The Engine Oil…………………………………………… 46
Cooling System…………………………………………………. 47
Checking The Coolant Level………………………………………. 47
Changing The Coolant……………………………………………. 48
Draining The Coolant……………………………………………. 48
Cleaning The Radiator And Adding Coolant………………………….. 49
Cleaning The Oil Cooler And The Radiator………………………….. 49
Hydraulic System……………………………………………….. 50
Checking The Hydraulic Oil Level…………………………………. 50
Draining The Hydraulic Oil………………………………………. 50
Replacing The Return Filter……………………………………… 51
Replacing The Hydraulic Filter…………………………………… 51
Cleaning The Suction Strainer……………………………………. 52
Adding Hydraulic Oil……………………………………………. 53
Fuel System……………………………………………………. 54
Fuel Specifications…………………………………………….. 54
Biodiesel Blend Fuel……………………………………………. 54
Draining The Contaminant From The Fuel Filter……………………… 55
Draining The Contaminant From The Fuel Tank……………………….. 55
Replacing The Fuel Filter Elements……………………………….. 55
Draining Fuel………………………………………………….. 56
Adding Fuel……………………………………………………. 56
Transmission System…………………………………………….. 57
Checking The Transmission Oil Level………………………………. 57
Draining Transmission Oil……………………………………….. 57
Replacing The Transmission Filter Elements………………………… 58
Adding Transmission Oil…………………………………………. 58
Front Drive Axle And Reduction Gears……………………………… 59
Front Drive Axle……………………………………………….. 59
Checking The Front Drive Axle Oil Level…………………………… 59
Draining Oil…………………………………………………… 59
Adding Oil…………………………………………………….. 59
Reduction Gears………………………………………………… 60
Checking The Reduction Gear Oil Level…………………………….. 60
Draining The Reduction Gear Oil………………………………….. 60
Adding The Reduction Gear Oil……………………………………. 60
Rear Axle……………………………………………………… 61
Checking The Rear Axle Oil Level…………………………………. 61
Cleaning The Rear Axle Breather………………………………….. 61
Draining Rear Axle Oil………………………………………….. 61
Adding Rear Axle Oil……………………………………………. 62
Bleeding The Brake System……………………………………….. 62
Service Schedule……………………………………………….. 63
AIR CLEANER SERVICE………………………………………………… 67
Engine Air Intake System………………………………………… 67
Cleaning The Primary Element…………………………………….. 68
Replacing The Air Filter Elements………………………………… 68
Cab Air Intake Filter…………………………………………… 69
BACKHOE BOOM / SWING LOCK…………………………………………… 71
Engaging And Disengaging………………………………………… 71
ENGINE ALTERNATOR / FAN BELTS AND AIR CONDITIONER BELT (IF EQUIPPED)…….. 73
Inspection…………………………………………………….. 73
Replacing The Alternator / Fan Belts……………………………… 73
Replacing The Air Conditioner Belt……………………………….. 73
TIRE MAINTENANCE…………………………………………………… 75
Description……………………………………………………. 75
Inspection…………………………………………………….. 75
Wheel Nuts…………………………………………………….. 75
Wheel Replacement………………………………………………. 76
LUBRICATING THE BACKHOE LOADER………………………………………. 77
Lubrication Locations…………………………………………… 77
HYDRAULIC SYSTEM………………………………………………………. 83
HYDRAULICE SCHEMATICS………………………………………………. 85
HYDRAULIC SYSTEM INFORMATION………………………………………… 87
Glossary Of Hydraulic / Hydrostatic Symbols……………………….. 87
HYDRAULIC SYSTEM…………………………………………………… 91
Tests And Hydraulic Pressure Test………………………………… 91
Test Ports…………………………………………………….. 92
Hydraulic Tank And Return Filter…………………………………. 93
Fixed Displacement Tandem Pump…………………………………… 94
Blocks………………………………………………………… 95
ON-OFF Solenoid Valve…………………………………………… 97
ON-OFF Pressure Reducing Valve…………………………………… 98
Loader Control Valve……………………………………………. 99
Unloading Valve Test…………………………………………….105
Steering Priority Valve………………………………………….106
Backhoe Control Valve……………………………………………107
Steering Pressure Test…………………………………………..109
Pilot Pressure Test……………………………………………..110
Pilot Pressure Regulation Block…………………………………..111
Priority Valve………………………………………………….112
RETURN LINE CHECK VALVE……………………………………………..115
Removal And Installation…………………………………………115
LOADER ARM LIFT CYLINDER…………………………………………….117
Removal And Installation…………………………………………117
Disassembly And Assembly…………………………………………118
LOADER BUCKET (TILT) CYLINDER………………………………………..119
Removal And Installation…………………………………………119
Disassembly And Assembly…………………………………………121
CLAMPSHELL CYLINDER…………………………………………………123
Removal And Installation…………………………………………123
Disassembly And Assembly…………………………………………124
BACKHOE BOOM CYLINDER……………………………………………….125
Removal And Installation…………………………………………125
Disassembly And Assembly…………………………………………127
BACKHOE ARM CYLINDER………………………………………………..129
Removal And Installation…………………………………………129
Disassembly And Assembly…………………………………………131
BACKHOE BUCKET CYLINDER……………………………………………..133
Removal And Installation…………………………………………133
Disassembly And Assembly…………………………………………134
BACKHOE EXTENDABLE ARM CYLINDER………………………………………135
Removal And Installation…………………………………………135
Disassembly And Assembly…………………………………………136
BACKHOE SWING CYLINDERS……………………………………………..137
Removal And Installation…………………………………………137
Disassembly And Assembly…………………………………………141
BACKHOE STABILIZER CYLINDER………………………………………….143
Removal And Installation…………………………………………143
Disassembly And Assembly…………………………………………146
CLAMP CYLINDERS…………………………………………………….147
Removal And Installation…………………………………………147
Disassembly And Assembly…………………………………………149
HYDRAULIC PUMP……………………………………………………..151
Removal And Installation…………………………………………151
BACKHOE CONTROL VALVE……………………………………………….153
Removal And Installation…………………………………………153
BRAKE PEDAL AND BOOSTER……………………………………………..161
Removal And Installation…………………………………………161
HYDRAULIC FLUID RESERVOIR……………………………………………163
Removal And Installation…………………………………………163
Hydraulic Fluid Screen Removal And Installation…………………….165
Hydraulic Filter Removal And Installation………………………….165
Hydraulic Suction Strainer Removal And Installation…………………166
LOADER CONTROL VALVE………………………………………………..169
Removal And Installation…………………………………………169
STEERING COLUMN AND UNIT…………………………………………….173
Removal And Installation…………………………………………173
ELECTRICAL SYSTEM………………………………………………………175
ELECTRICAL SCHEMATICS……………………………………………….177
ELECTRICAL SYSTEM INFORMATION………………………………………..179
Component Location………………………………………………179
BATTERY……………………………………………………………189
Removal And Installation…………………………………………189
Inspection And Maintenance……………………………………….190
FUSES……………………………………………………………..191
Component Location………………………………………………191
Parts Identification…………………………………………….192
Removal And Installation…………………………………………193
RELAYS…………………………………………………………….195
Component Location………………………………………………195
Parts Identification…………………………………………….196
Removal And Installation…………………………………………197
RIGHT CONTROL PANEL…………………………………………………199
Removal And Installation…………………………………………199
STARTER……………………………………………………………203
Removal And Installation…………………………………………203
ALTERNATOR…………………………………………………………205
Removal And Installation…………………………………………205
AXLES…………………………………………………………………207
SAFTEY INSTRUCTIONS…………………………………………………209
General Safety Recommendations……………………………………209
FRONT AXLE…………………………………………………………211
Description…………………………………………………….211
Removal And Installation…………………………………………212
Tightening Torques………………………………………………214
Steering Cylinder Group Disassembly……………………………….216
Steering Cylinder Group Assembly………………………………….220
Epicyclic Reduction Gear Group Disassembly…………………………224
Epicyclic Reduction Gear Group Assembly……………………………226
Wheel Hub Group Disassembly………………………………………228
Wheel Hub Group Assembly…………………………………………232
Axle Beam Group Disassembly………………………………………236
Axle Beam Group Assembly…………………………………………238
Flange Group Disassembly…………………………………………240
Flange Group Assembly……………………………………………241
Differential Support Group Disassembly…………………………….242
Differential Support Group Assembly……………………………….244
Differential Group Disassembly……………………………………250
Differential Group Assembly………………………………………252
Pinion Group Disassembly…………………………………………253
Pinion Group Assembly……………………………………………256
Toe-in / Steering Angle………………………………………….261
Steering Angle Adjustment………………………………………..264
Testing After Assembly…………………………………………..265
FRONT SHAFT………………………………………………………..267
Removal And Installation…………………………………………267
REAR SHAFT…………………………………………………………269
Removal And Installation…………………………………………269
REAR AXLE………………………………………………………….271
Description…………………………………………………….271
Removal And Installation…………………………………………272
Tightening Torques………………………………………………275
Steering Cylinder Group Disassembly……………………………….278
Steering Cylinder Group Assembly………………………………….282
Epicyclic Reduction Gear Group Disassembly…………………………287
Epicyclic Reduction Gear Group Assembly……………………………289
Wheel Hub Group Disassembly………………………………………291
Wheel Hub Group Assembly…………………………………………295
Parking Brake Group Disassembly…………………………………..299
Parking Brake Group Assembly……………………………………..302
Parking Brake Caliper……………………………………………304
Axle Beam Trumpet Group Disassembly……………………………….306
Axle Beam Trumpet Group Assembly………………………………….309
Brake Group…………………………………………………….312
Brake Group Disassembly………………………………………….313
Brake Group Assembly…………………………………………….315
Differential Support Group Disassembly…………………………….319
Differential Support Group Assembly……………………………….322
Differential Group Disassembly……………………………………328
Differential Group Assembly………………………………………330
Differential Lock……………………………………………….332
Differential Locking Group Disassembly…………………………….334
Differential Locking Group Assembly……………………………….336
Pinion Group Disassembly…………………………………………339
Pinion Group Assembly……………………………………………342
Toe-In / Steering Angle………………………………………….348
Steering Angle Adjustment………………………………………..350
Testing After Assembly…………………………………………..351
SERVICE BRAKE………………………………………………………353
Description…………………………………………………….353
Bleeding The Brake Circuitry……………………………………..353
Test Procedure………………………………………………….354
Brake System Troubleshooting……………………………………..355
TRANSMISSION…………………………………………………………..357
MANUAL USE…………………………………………………………359
Maintenance…………………………………………………….359
Repair…………………………………………………………359
Agreements And Definitions……………………………………….359
Typographic Agreements…………………………………………..359
Measurements……………………………………………………359
General Description……………………………………………..359
Recommendations For Repair Operations……………………………..360
Transmission Installation On The Machine…………………………..361
SAFETY INSTRUCTIONS…………………………………………………363
General Safety Recommendations……………………………………363
TRANSMISSION……………………………………………………….365
Component Location………………………………………………365
Tightening Torques………………………………………………370
Hydraulic Schematic……………………………………………..373
Main Hydraulic Components………………………………………..374
Kinematic Scheme………………………………………………..375
Plugs And Filters Disassembly…………………………………….376
Removal And Installation…………………………………………377
Plugs And Filters Disassembly…………………………………….382
Plugs And Filters Assembly……………………………………….386
Torque Converter And Oil Pump Disassembly………………………….389
Torque Converter And Oil Pump Assembly…………………………….392
Hydraulic Control Valve Disassembly……………………………….394
Hydraulic Control Valve Assembly………………………………….398
Hydraulic System Pipes Disassembly………………………………..400
Hydraulic System Pipes Assembly…………………………………..402
Transmission Housing Disassembly………………………………….403
Transmission Housing Assembly…………………………………….409
Shafts A – D Disassembly…………………………………………414
Shafts A – D Assembly……………………………………………424
Axis B Disassembly………………………………………………435
Axis B Assembly…………………………………………………443
Axis C Disassembly………………………………………………451
Axis C Assembly…………………………………………………466
Axis E Disassembly………………………………………………483
Axis E Assembly…………………………………………………489
ENGINE SERVICE…………………………………………………………499
GENERAL ENGINE INFORMATION…………………………………………..503
Introduction……………………………………………………503
Engine Views……………………………………………………503
Engine Identification……………………………………………504
Safety Precautions………………………………………………505
Engine Lift Equipment……………………………………………507
Viton Seals…………………………………………………….508
Safety Cautions When an Engine in Cleaned………………………….508
POWERPART Recommended Consumable Products………………………….509
Troubleshooting…………………………………………………511
ENGINE SPECIFICATIONS……………………………………………….515
Basic Engine Data……………………………………………….515
Data And Dimensions……………………………………………..516
Thread Sealant………………………………………………….535
Standard Torque Values…………………………………………..536
Specific Torque Values…………………………………………..537
Compression Test Data……………………………………………540
CYLINDER HEAD………………………………………………………541
General Description……………………………………………..541
Atomiser Cover………………………………………………….541
Rocker Cover……………………………………………………542
Rocker Arm……………………………………………………..544
Valve Tip Clearances…………………………………………….546
Valve Springs…………………………………………………..547
Removal………………………………………………………..549
Installation……………………………………………………551
Valve And Valve Springs………………………………………….554
Valve Guides……………………………………………………557
Inspection And To Correct………………………………………..560
PISTON AND CONNECTING ROD ASSEMBLIES………………………………….563
General Description……………………………………………..563
Big End Bearing…………………………………………………564
Piston And Connecting Rod………………………………………..566
Piston Rings……………………………………………………569
Piston And Connecting Rod Assembly………………………………..570
Piston And Piston Rings………………………………………….572
Connecting Rod………………………………………………….573
Partially Finished Small End Bush…………………………………573
Piston Cooling Jets……………………………………………..574
CRANKSHAFT ASSEMBLY…………………………………………………575
General Description……………………………………………..575
Crankshaft Pulley……………………………………………….576
Rear End Oil Seal Assembly……………………………………….577
To Remove And To Fit A Wear Sleeve………………………………..583
Thrust Washers………………………………………………….584
Main Bearings…………………………………………………..588
Crankshaft……………………………………………………..590
Balancer Unit…………………………………………………..594
TIMING CASE AND DRIVE ASSEMBLY……………………………………….599
General Description……………………………………………..599
Timing Cover……………………………………………………600
Mechanical Fuel Pump Gear………………………………………..602
Electronic Fuel Pump Gear………………………………………..606
Idler Gear and Hub………………………………………………608
Heavy Duty Idler Gear……………………………………………611
Camshaft Gear…………………………………………………..613
Front Oil Seal………………………………………………….614
Timing Case…………………………………………………….617
Crankshaft Gear…………………………………………………620
Camshaft and Tappets…………………………………………….621
CYLINDER BLOCK ASSEMBLY……………………………………………..623
General Description……………………………………………..623
Cylinder Block………………………………………………….623
Cylinder Bore…………………………………………………..625
ENGINE TIMING………………………………………………………627
General Description……………………………………………..627
To Set Number 1 Piston To TDC On The Compression Stroke……………..628
To Check The Timing Of The Bosch VP30 Fuel Injection Pump……………630
To Check The Timing Of The Bosch EPVE Fuel Injection Pump……………631
To Adjust The Timing Of The Bosch EPVE Fuel Injection Pump…………..632
To Check The Timing Of The Delphi DP210 Fuel Injection Pump………….633
To Check The Valve Timing………………………………………..634
ASPERATION SYSTEM…………………………………………………..635
General Description……………………………………………..635
Exhaust Elbow…………………………………………………..636
Turbocharger Side Mount………………………………………….637
Turbocharger Faults……………………………………………..640
Open Engine Breather…………………………………………….642
Natural Aspirated Engine Breather…………………………………643
Closed Engine Breather…………………………………………..644
LUBRICATION SYSTEM………………………………………………….645
General Description……………………………………………..645
Lubrication System Flow Diagram…………………………………..646
Canister Type Oil Filter…………………………………………647
Element Type Oil Filter………………………………………….648
Filter Head…………………………………………………….649
Sump…………………………………………………………..650
Dipstick Tube…………………………………………………..652
Oil Strainer And Suction Pipe…………………………………….653
Lubricating Oil Pump Assembly…………………………………….654
Relief Valve……………………………………………………656
FUEL SYSTEM………………………………………………………..659
General Description……………………………………………..659
Cold Start Advance Unit (KSB)…………………………………….661
Typical Fuel System……………………………………………..662
Fuel Filter Assembly…………………………………………….663
Atomizers………………………………………………………664
Fuel Lift Pump And Filter Assembly………………………………..667
Removing Air From The Fuel System…………………………………669
Bosch VP30 Fuel Injection Pump……………………………………670
Bosch EVPE Fuel Injection Pump……………………………………675
Delphi DP210 Fuel Injection Pump………………………………….678
COOLING SYSTEM……………………………………………………..683
General Description……………………………………………..683
Coolant Flow Diagram…………………………………………….684
Thermostat……………………………………………………..685
Coolant Pump……………………………………………………689
Fan……………………………………………………………694
Fan Drive………………………………………………………694
Lubricating Oil Cooler…………………………………………..695
Coolant Bypass Pipe……………………………………………..697
Oil Cooler / Radiator Removal And Installation……………………..698
FLYWHEEL AND HOUSING………………………………………………..701
General Description……………………………………………..701
Flywheel……………………………………………………….701
Ring Gear………………………………………………………701
Flywheel Housing………………………………………………..702
ELECTRICAL SYSTEM…………………………………………………..703
General Description……………………………………………..703
Alternator……………………………………………………..703
Starting Aid (Glow Plug)…………………………………………709
Electrical Components……………………………………………711
Engine Control Module (ECM)………………………………………713
Voltage Load Protection Module……………………………………715
Programming A New ECM……………………………………………716
Speed And Timing Sensor………………………………………….717
Pressure Sensor…………………………………………………718
Temperature Sensor………………………………………………720
Wiring Harness………………………………………………….722
AUXILIARY EQUIPMENT…………………………………………………729
Power Steering Pump……………………………………………..729
Adaptor For A Hydraulic Pump Or A Steering Pump…………………….730
Exhauster………………………………………………………732
SPECIAL TOOLS………………………………………………………733
REAR HAND THROTTLE LEVER…………………………………………….737
Cable Adjustment Procedure……………………………………….737
ACCELERATOR PEDAL…………………………………………………..739
Removal And Installation…………………………………………739
Cable Adjustment Procedure……………………………………….741
EXHAUST……………………………………………………………743
Removal And Installation…………………………………………743
AIR FILTER…………………………………………………………745
Housing Removal And Installation………………………………….745
ENGINE…………………………………………………………….747
Removal And Installation…………………………………………747
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)…………………………..753
HVAC UNIT………………………………………………………….755
Parts Identification…………………………………………….755
Compressor Removal And Installation……………………………….756
Receiver Removal And Installation…………………………………756
Condenser Removal And Installation………………………………..757
Evaporator-heater Unit Removal And Installation…………………….757
Evaporator-heater Unit Disassembly And Assembly…………………….761
MAIN FRAME…………………………………………………………….763
BACKHOE BOOM / SWING LOCK……………………………………………765
Removal And Installation…………………………………………765
BACKHOE BUCKET……………………………………………………..767
Removal And Installation…………………………………………767
Teeth Removal And Installation……………………………………767
LOADER BUCKET………………………………………………………769
Removal And Installation…………………………………………769
Teeth Removal And Installation……………………………………770
BACKHOE BOOM……………………………………………………….771
Removal And Installation…………………………………………771
CAB……………………………………………………………….773
Removal And Installation…………………………………………773
COUNTERWEIGHT………………………………………………………781
Removal And Installation…………………………………………781
ENGINE COVER……………………………………………………….783
Removal And Installation…………………………………………783
ENGINE SIDE COVERS………………………………………………….785
Removal And Installation…………………………………………785
FRONT MUDGUARD……………………………………………………..787
Removal And Installation…………………………………………787
PARKING LEVER………………………………………………………789
Removal And Installation…………………………………………789
FUEL TANK………………………………………………………….791
Removal And Installation…………………………………………791
GRILLE FRAME……………………………………………………….793
Removal And Installation…………………………………………793
GRILLE…………………………………………………………….795
Removal And Installation…………………………………………795
KINGPOST…………………………………………………………..797
Removal And Installation…………………………………………797
SIDE SHIFT…………………………………………………………801
Removal And Installation…………………………………………801
BACKHOE ARM………………………………………………………..803
Removal And Installation…………………………………………803
FRONT CONSOLE………………………………………………………807
Removal And Installation…………………………………………807
STABILIZER WEAR PADS………………………………………………..811
Adjustment……………………………………………………..811
LOADER LIFT ARMS……………………………………………………813
Removal And Installation…………………………………………813
REAR WINDOW………………………………………………………..815
Removal And Installation…………………………………………815
CAB DOOR…………………………………………………………..817
Removal And Installation…………………………………………817
FLOOR PANELS……………………………………………………….819
Removal And Installation…………………………………………819
OPERATOR SEAT………………………………………………………821
Removal And Installation…………………………………………821
WINDOW FLUID RESERVOIR………………………………………………823
Removal And Installation…………………………………………823
ALPHABETICAL INDEX……………………………………………………..825

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DESCRIPTION:

BOBCAT B780 Backhoe Loader Service Manual SN B4U311001 PDF DOWNLOAD

SAFETY INSTRUCTIONS (CONT’D)
General Safety Information

Study the Operation & Maintenance Manual before operating or working on the backhoe loader, make sure that you have additional information for special attachments of your machine, read it and understand it!

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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