Bobcat S70 Skid-Steer Loader Service Manual 6986662 – PDF DOWNLOAD

Description

Bobcat S70 Skid-Steer Loader Service Manual 6986662 – PDF DOWNLOAD

FILE DETAILS:

Bobcat S70 Skid-Steer Loader Service Manual 6986662 – PDF DOWNLOAD

Language : English
Pages : 528
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S70 Skid-Steer Loader Service Manual 6986662 – PDF DOWNLOAD

S/N A3W611001 & Above
S/N A3W711001 & Above
S/N B38V11001 & Above
S/N B38W11001 & Above
S/N B4TY11001 & Above
S/N B4UC11001 & Above

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.

A general inspection of the following items must be made after the loader has had service or repair:

TABLE OF CONTENTS:

Bobcat S70 Skid-Steer Loader Service Manual 6986662 – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Loader Serial Number 15
Engine Serial Number 15
LOADER IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE LOADER 23
Procedure 23
LIFT ARM SUPPORT DEVICE 25
Installing 25
Removing 27
OPERATOR CAB 29
Description 29
Raising 30
Lowering 31
Special Applications Kit 33
Special Applications Kit Inspection And Maintenance 33
TRANSPORTING THE LOADER ON A TRAILER 35
Loading And Unloading 35
Fastening 36
TOWING THE LOADER 37
Procedure 37
REMOTE START TOOL KIT – MEL1563 39
Remote Start Tool – MEL1563 39
Service Tool Harness Communicator – MEL1566 40
Remote Start Procedure 41
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666 45
Description 45
Remote Start Tool (Service Tool) – 7022042 46
Loader Service Tool Harness – 6689747 47
Computer Service Tool Harness – 6689746 49
Remote Start Procedure 49
SERVICE SCHEDULE 53
Chart 53
AIR CLEANER SERVICE 55
Replacing Filter Elements 55
ENGINE COOLING SYSTEM 57
Cleaning 57
Checking Level 58
Removing And Replacing Coolant 59
FUEL SYSTEM 61
Fuel Specifications 61
Biodiesel Blend Fuel 61
Filling The Fuel Tank 62
Fuel Filter 63
Removing Air From The Fuel System 64
ENGINE LUBRICATION SYSTEM 65
Checking And Adding Engine Oil 65
Engine Oil Chart 65
Removing And Replacing Oil And Filter 66
HYDRAULIC / HYDROSTATIC SYSTEM 67
Checking And Adding Fluid 67
Hydraulic / Hydrostatic Fluid Chart 67
Removing And Replacing Hydraulic Fluid 68
Removing And Replacing Hydraulic / Hydrostatic Filter 69
Breather Cap 70
FINAL DRIVE TRANSMISSION (CHAINCASE) 71
Checking And Adding Oil 71
Removing And Replacing Oil 71
AUXILIARY CONTROL LOCKBOLT 73
Procedure 73
BOB-TACH 75
Inspection And Maintenance 75
LUBRICATING THE LOADER 77
Lubrication Locations 77
TIRE MAINTENANCE 79
Wheel Nuts 79
Rotating 79
Mounting 80
SPARK ARRESTER MUFFLER 81
Cleaning Procedure 81
PIVOT PINS 83
Inspection And Maintenance 83
SEAT BAR RESTRAINT SYSTEM 85
Description 85
Inspecting 85
Maintaining 86
LOADER STORAGE AND RETURN TO SERVICE 87
Storage 87
Return To Service 87
STOPPING THE ENGINE AND LEAVING THE LOADER 89
Procedure 89
EMERGENCY EXIT 91
Rear Window 91
Front Door 91
SEAT BELT 93
Inspection And Maintenance 93
HYDRAULIC SYSTEM 95
HYDRAULIC/HYDROSTATIC SCHEMATIC 99
HYDRAULIC SYSTEM INFORMATION 101
Glossary Of Hydraulic / Hydrostatic Symbols 101
Troubleshooting Chart 105
CYLINDER (LIFT) 107
Testing 107
Removal And Installation 108
Parts Identification 110
Disassembly And Assembly 111
CYLINDER (TILT) 115
Testing 115
Removal And Installation 116
Parts Identification 117
Disassembly And Assembly 118
MAIN RELIEF VALVE 121
Description 121
Testing Without Auxiliaries 122
Testing With Auxiliaries 123
Removal And Installation 124
HYDRAULIC CONTROL VALVE 125
Description 125
BICS™ Valve Removal And Installation 126
BICS™ Valve, Lift Arm Bypass Orifice Removal And Installation 127
Pressure Differential Valve Removal And Installation 128
BICS™ Valve, Check Valve Removal And Installation 129
BICS™ Valve, Solenoid Removal And Installation 130
BICS™ Valve, Solenoid Testing 131
BICS™ Valve, Identification Chart 131
Removal And Installation 132
Identification Chart 134
Disassembly And Assembly 135
Load Check Valves Removal And Installation 135
Main Relief Valve Removal And Installation 136
Port Relief / Anti-Cavitation Valve Removal And Installation 137
Anti-Cavitation / Check Valves Removal And Installation 138
Rubber Boot Removal And Installation 139
Lift And Tilt Lock Block Removal And Installation 139
Lift Spool And Detent Removal And Installation 140
Lift Spool And Detent Disassembly 142
Lift Spool And Detent Assembly 144
Tilt Spool Removal And Installation 146
Tilt Spool Disassembly And Assembly 147
Auxiliary Spool Removal And Installation 148
Auxiliary Spool Disassembly And Assembly 149
Spool Seal Installation 152
Auxiliary Pivot Bracket Removal And Installation 153
Auxiliary Pivot Bracket Disassembly And Assembly 153
LIFT ARM BYPASS CONTROL VALVE 155
Description 155
Testing 155
Removal And Installation 156
Disassembly And Assembly 157
HYDRAULIC PUMP 159
Description 159
Direct Pump Testing 159
Removal And Installation 161
Hydraulic Pump Startup 163
Parts Identification 164
Disassembly And Assembly 165
HYDRAULIC / HYDROSTATIC FILTER 167
Description 167
Housing Removal And Installation 167
Housing Disassembly And Assembly 169
HYDRAULIC FLUID RESERVOIR 171
Description 171
Removal And Installation 172
OIL COOLER 175
Description 175
Removal And Installation 176
BUCKET POSITION VALVE 179
Description 179
Solenoid Removal And Installation 179
Solenoid Testing 180
Removal And Installation 181
Disassembly And Assembly 183
AUXILIARY HYDRAULIC INTERLOCK VALVE 185
Description 185
Removal And Installation 185
Disassembly And Assembly 186
HYDROSTATIC SYSTEM 189
HYDROSTATIC SYSTEM INFORMATION 191
Description 191
Troubleshooting 192
HYDROSTATIC DRIVE MOTOR 193
Description 193
Removal And Installation 193
Parts Identification 195
Disassembly 196
Assembly 202
CHARGE PRESSURE 207
Description 207
Testing 207
Sender Removal And Installation 209
HYDROSTATIC PUMP 211
Description 211
Replenishing / High Pressure Relief Valve Removal And Installation 211
Removal And Installation 212
Parts Identification 215
Disassembly 216
Assembly 221
DRIVE BELT 225
Description 225
Adjusting 225
Belt Removal And Installation 225
Tensioner Pulley Removal And Installation 226
Tensioner Pulley Disassembly And Assembly 226
DRIVE SYSTEM 227
BRAKE 229
Description 229
Disc Removal And Installation 229
DRIVE COMPONENTS 231
Description 231
Axle Seal Removal And Installation 232
Axle, Sprocket And Bearings Removal And Installation 234
Chain Removal And Installation 238
CHAINCASE 239
Description 239
Chaincase Cover Removal And Installation 239
Chaincase Cover Disassembly And Assembly 240
MAINFRAME 241
SEAT BAR 243
Description 243
Removal And Installation 243
Disassembly And Assembly 246
Compression Spring Disassembly And Assembly 247
OPERATOR CAB 249
Gas Cylinder Removal And Installation 249
Removal And Installation 251
OPERATOR SEAT 253
Removal And Installation 253
Seat Belt Removal And Installation 253
BOB-TACH 255
Description 255
Removal And Installation 255
Lever And Wedge Disassembly And Assembly 257
LIFT ARMS 259
Removal And Installation 259
REAR DOOR 263
Removal And Installation 263
FUEL TANK 265
Removal And Installation 265
CONTROL PEDALS AND LINKAGES 267
Description 267
Pedal Removal And Installation 267
Pedal Interlock Linkage Removal And Installation 268
CONTROL PANEL 269
Description 269
Control Shield And Steering Lever Panels Removal And Installation 269
CONTROL LEVER 271
Description 271
Lever Removal And Installation 271
Lever Disassembly And Assembly 273
Linkage Neutral Adjustment 274
Pintle Arm Removal 275
Pintle Arm Installation 278
Pintle Arm Disassembly And Assembly 280
WINDOW (REAR) 281
Removal 281
Installation 281
WINDOW (TOP) 283
Removal 283
Installation 284
ELECTRICAL SYSTEM AND ANALYSIS 285
ELECTRICAL SCHEMATIC 289
ELECTRICAL SYSTEM INFORMATION 315
Glossary Of Electrical Symbols 315
Cab Harness Connectors 318
Mainframe Harness Connectors 319
Description 320
Troubleshooting 321
Fuse And Relay Location / Identification 322
Solenoid Testing 323
BATTERY 325
Removal And Installation 325
Battery Maintenance 326
Maintaining Battery Charge Level 326
Battery Service During Machine Storage 326
Battery Testing 327
Battery Charging 327
Using A Booster Battery (Jump Starting) 328
Removing And Installing Battery 330
ALTERNATOR 331
Belt Adjustment 331
Belt Replacement 331
Charging System Inspection 332
Alternator Voltage Testing 333
Low Voltage Testing 333
High Voltage Testing 334
Removal And Installation 335
Parts Identification 336
STARTER 337
Testing 337
Removal And Installation 339
Parts Identification 340
INSTRUMENT PANELS 341
Left And Right Panels 341
Standard Key Panel 342
Keyless Start Panel 342
Option And Field Accessory Panel 343
Left And Right Removal And Installation 344
LIGHTS 345
Front Removal And Installation 345
Rear Removal And Installation 346
Cab Light Removal And Installation (Earlier Models) 347
Cab Light Removal And Installation (Later Models) 348
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 349
Description 349
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 350
Inspecting The Seat Bar Sensor (Engine RUNNING) 350
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 350
Inspecting The Lift Arm Bypass Control 350
Inspecting Deactivation Of The Auxiliary Hydraulics System 351
BOBCAT CONTROLLER (GATEWAY) 353
Description 353
Troubleshooting 353
Viewing Diagnostic Service Codes 354
Removal And Installation 355
SEAT BAR SENSOR 357
Description 357
Troubleshooting 357
Testing 358
Removal And Installation 359
Bobcat Interlock Control System (BICS™) Circuit Test 361
TRACTION LOCK 363
Description 363
Troubleshooting 363
Removal And Installation 364
BACK-UP ALARM SYSTEM (S/N A3W611001 – A3W613689 AND A3W711001 – A3W713379) 367
Description 367
Inspecting 367
Adjusting Switch Position 368
Troubleshooting 369
Alarm Removal And Installation 370
Switch Removal And Installation 371
BACK-UP ALARM SYSTEM (S/N A3W613690 & ABOVE, A3W713380 & ABOVE, B38V11001 & ABOVE, B38W11001 & ABOVE) 373
Description 373
Inspecting 373
Troubleshooting 374
Switch Removal And Installation 375
Alarm Removal And Installation 376
BACK-UP ALARM SYSTEM (S/N B4TY11001 & ABOVE AND B4UC11001 & ABOVE) 377
Description 377
Inspecting 377
Adjusting Switch Position 377
Troubleshooting 378
Alarm Removal And Installation 379
Switch Removal And Installation 379
ENGINE SERVICE 381
ENGINE INFORMATION 383
Description 383
Specifications 384
Torque Values 388
Troubleshooting 389
Engine Removal And Installation 391
Engine Mount Replacement 397
Compression – Checking 398
ENGINE SPEED CONTROL 399
Removal And Installation 399
MUFFLER 401
Removal And Installation 401
AIR CLEANER 403
Housing Removal And Installation 403
ENGINE COOLING SYSTEM 405
Radiator Removal And Installation 405
Fan Removal And Installation 407
Water Pump Removal And Installation 407
Water Pump Disassembly And Assembly 408
Thermostat Housing Removal And Installation 408
LUBRICATION SYSTEM 409
Oil Pan Removal And Installation 409
Oil Pump Removal And Installation 410
Oil Pump Inspection 410
Engine Oil Pressure – Testing 412
FUEL SYSTEM 413
Fuel Camshaft Removal And Installation 413
Governor Shaft Removal And Installation 415
Governor Fork Lever Removal And Installation 418
Fuel ShutOff Solenoid – Checking 420
Fuel ShutOff Solenoid Removal And Installation 420
Fuel Injection Pump Removal And Installation 421
Fuel Injection Pump Timing 423
Fuel Injector Nozzles Removal And Installation 424
Fuel Injector Nozzle Pressure – Checking 425
Nozzle Spray Condition 426
Valve Seat Tightness 427
CYLINDER HEAD 429
Glow Plug – Checking 429
Glow Plug Removal And Installation 429
Valve Clearance Adjustment 430
Valve Timing Checking 431
Cylinder Head Removal And Installation 431
Cylinder Head Disassembly And Assembly 434
Cylinder Head – Servicing 434
Cylinder Head Top Clearance 435
Valve Guide – Checking 435
Reconditioning The Valve And Valve Seat 437
Valve Spring 438
Valve Tappets 439
Rocker Arm And Shaft – Checking 439
CRANKSHAFT AND PISTONS 441
Piston And Connecting Rod Removal And Installation 441
Piston And Connecting Rod – Servicing 442
Cylinder Bore – Checking 445
Connecting Rod Alignment 445
Crankshaft And Bearings Removal And Installation 446
Crankshaft And Bearings – Servicing 448
CAMSHAFT AND TIMING GEARS 453
Timing Gearcase Cover Removal And Installation 453
Timing Gears Backlash – Checking 455
Idler Gear And Shaft Removal And Installation 455
Camshaft – Servicing 456
Idler Gear And Shaft Servicing 458
FLYWHEEL AND HOUSING 459
Flywheel Removal And Installation 459
Ring Gear Removal And Installation 459
Housing Removal And Installation 460
HEATER 461
HEATER SYSTEM 463
Description 463
REGULAR MAINTENANCE (S/N A3W611001 – A3W613399 AND A3W711001 – A3W713235) 465
Heater Coil 465
REGULAR MAINTENANCE (S/N A3W613400 & ABOVE, A3W713236 & ABOVE, B38V11001 & ABOVE, B38W11001 & ABOVE, B4TY11001 & ABOVE AND B4UC11001 & ABOVE) 467
Heater Coil 467
TROUBLESHOOTING 469
Electric System 469
Heater Valve Not Opening Or Closing 469
Blower Motor Does Not Operate 469
Blower Motor Operates Normally, But Air Flow Is Insufficient 469
HEATER UNIT (S/N A3W611001 – A3W613399 AND A3W711001 – A3W713235) 471
Removal And Installation 471
HEATER UNIT (S/N A3W613400 & ABOVE, A3W713236 & ABOVE, B38V11001 & ABOVE, B38W11001 & ABOVE, B4TY11001 & ABOVE AND B4UC11001 & ABOVE) 473
Removal And Installation 473
HEATER COIL (S/N A3W611001 – A3W613399 AND A3W711001 – A3W713235) 475
Removal And Installation 475
HEATER COIL (S/N A3W613400 & ABOVE, A3W713236 & ABOVE, B38V11001 & ABOVE, B38W11001 & ABOVE, B4TY11001 & ABOVE AND B4UC11001 & ABOVE) 477
Removal And Installation 477
HEATER FAN (S/N A3W611001 – A3W613399 AND A3W711001 – A3W713235) 479
Removal And Installation 479
HEATER FAN (S/N A3W613400 & ABOVE, A3W713236 & ABOVE, B38V11001 & ABOVE, B38W11001 & ABOVE, B4TY11001 & ABOVE AND B4UC11001 & ABOVE) 481
Removal And Installation 481
HEATER VALVE (S/N A3W611001 – A3W613399 AND A3W711001 – A3W713235) 483
Removal And Installation 483
HEATER VALVE (S/N A3W613400 & ABOVE, A3W713236 & ABOVE, B38V11001 & ABOVE, B38W11001 & ABOVE, B4TY11001 & ABOVE AND B4UC11001 & ABOVE) 485
Removal And Installation 485
HEATER SWITCH (S/N A3W611001 – A3W613399 AND A3W711001 – A3W713235) 487
Removal And Installation 487
Checking 488
HEATER SWITCH (S/N A3W613400 & ABOVE, A3W713236 & ABOVE, B38V11001 & ABOVE, B38W11001 & ABOVE, B4TY11001 & ABOVE AND B4UC11001 & ABOVE) 489
Removal And Installation 489
Checking 490
SPECIFICATIONS 491
(S70) LOADER SPECIFICATIONS 493
Machine Dimensions 493
Performance (A3W6, A3W7, B38V, B38W 11001 & Above) 494
Performance (B4TY11001 & Above And B4UC11001 & Above) 494
Engine 494
Drive System 496
Controls 496
Hydraulic System 497
Electrical 497
Capacities 498
Tires 498
TECHNICAL SERVICE GUIDE SPECIFICATIONS 499
Engine 499
Engine Torques 499
Cooling System 499
Loader Torques 500
Hydraulic / Hydrostatic System 500
Fuel Consumption 500
TORQUE SPECIFICATIONS FOR BOLTS 501
Torque For General SAE Bolts 501
Torque For General Metric Bolts 502
HYDRAULIC CONNECTION SPECIFICATIONS 503
O-ring Face Seal Connection 503
Straight Thread O-ring Fitting 504
Tubelines And Hoses 504
Flare Fitting 504
Port Seal Fitting 505
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 507
Specifications 507
CONVERSIONS 509
Decimal And Millimeter Equivalent Chart 509
U S To Metric Conversion Chart 509
SERVICE TOOLS REQUIRED 511
Remote Start Tools 511
Hydraulic Tools 512
Mainframe And Drive Tools 515
Electrical Tools 518
Engine Tools 519
HVAC Tools 524
ALPHABETICAL INDEX 525

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