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Bobcat T770 Compact Track Loader Service Manual 6990265 – PDF DOWNLOAD
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Bobcat T770 Compact Track Loader Service Manual 6990265 – PDF DOWNLOAD
S/N AN8T11001 & Above
S/N ATF711001 & Above
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Description
Bobcat T770 Compact Track Loader Service Manual 6990265 – PDF DOWNLOAD
FILE DETAILS:
Bobcat T770 Compact Track Loader Service Manual 6990265 – PDF DOWNLOAD
Language : English
Pages : 1100
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T770 Compact Track Loader Service Manual 6990265 – PDF DOWNLOAD
S/N AN8T11001 & Above
S/N ATF711001 & Above
TABLE OF CONTENTS:
Bobcat T770 Compact Track Loader Service Manual 6990265 – 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 DELIVERY REPORT............................................................................. 16 LOADER IDENTIFICATION....................................................................... 17 SAFETY AND MAINTENANCE.......................................................................... 19 LIFTING AND BLOCKING THE LOADER............................................................. 23 Procedure............................................................................... 23 LIFT ARM SUPPORT DEVICE..................................................................... 25 Description............................................................................. 25 Installing.............................................................................. 25 Removing................................................................................ 26 OPERATOR CAB................................................................................ 27 Description............................................................................. 27 Raising................................................................................. 28 Lowering................................................................................ 29 Cab Door Sensor......................................................................... 30 Special Applications Kit................................................................ 31 Special Applications Kit Inspection And Maintenance..................................... 31 Forestry Door And Window Kit............................................................ 31 Forestry Door And Window Kit Inspection And Maintenance................................. 32 TRANSPORTING THE 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 - 7217666.............................................. 43 Description............................................................................. 43 Remote Start Tool (Service Tool) - 7022042.............................................. 44 Loader Service Tool Harness - 6689747................................................... 45 Computer Service Tool Harness - 6689746................................................. 46 Remote Start Procedure.................................................................. 47 DIAGMASTER (SERVICE TOOL) KIT - 7024161..................................................... 51 Diagmaster (Service Tool)............................................................... 51 DST-i LED Table......................................................................... 52 DST-i Operation Status And Display Specification........................................ 52 Diagmaster (Service Tool) Procedure..................................................... 53 SERVICE SCHEDULE............................................................................ 57 Maintenance Intervals................................................................... 57 ENGINE AIR CLEANER.......................................................................... 59 Replacing Filter Elements............................................................... 59 ENGINE COOLING SYSTEM....................................................................... 61 Maintenance Platform.................................................................... 61 Cleaning................................................................................ 61 Checking And Adding Coolant............................................................. 63 Removing And Replacing Coolant.......................................................... 64 FUEL SYSTEM................................................................................. 65 Fuel Specifications..................................................................... 65 Biodiesel Blend Fuel.................................................................... 65 Filling The Fuel Tank................................................................... 66 Fuel Filter............................................................................. 67 Removing Air From The Fuel System....................................................... 68 ENGINE LUBRICATION SYSTEM................................................................... 69 Checking And Adding Engine Oil.......................................................... 69 Engine Oil Chart........................................................................ 69 Removing And Replacing Oil And Filter................................................... 70 Removing And Replacing Crankcase Ventilation Filter..................................... 72 HYDRAULIC / HYDROSTATIC SYSTEM.............................................................. 73 Checking And Adding Fluid............................................................... 73 Hydraulic / Hydrostatic Fluid Chart..................................................... 73 Removing And Replacing Hydraulic Fluid.................................................. 74 Removing And Replacing Hydraulic / Hydrostatic Filter................................... 76 Removing And Replacing Hydraulic Charge Filter.......................................... 77 Replacing Reservoir Breather Cap........................................................ 79 BOB-TACH (HAND LEVER)....................................................................... 81 Inspection And Maintenance.............................................................. 81 BOB-TACH (POWER)............................................................................ 83 Inspection And Maintenance.............................................................. 83 LUBRICATING THE LOADER...................................................................... 85 Lubrication Locations................................................................... 85 DIESEL PARTICULATE FILTER (DPF) SYSTEM...................................................... 89 Description............................................................................. 89 Remote Parked Regeneration.............................................................. 89 Service Regeneration.................................................................... 91 DPF Cleaning............................................................................ 91 PIVOT PINS.................................................................................. 93 Inspection And Maintenance.............................................................. 93 LOADER STORAGE AND RETURN TO SERVICE........................................................ 95 Storage................................................................................. 95 Return To Service....................................................................... 95 STOPPING THE ENGINE AND LEAVING THE LOADER.................................................. 97 Procedure............................................................................... 97 EMERGENCY EXIT.............................................................................. 99 Rear Window Identification.............................................................. 99 Rear Window Removal (Latches)........................................................... 99 Rear Window Removal (Rubber Cord)....................................................... 99 External Access (Rear Window With Latches).............................................. 100 External Access (Rear Window With Rubber Cord).......................................... 100 Front Door.............................................................................. 100 SEAT BELT................................................................................... 103 Inspection And Maintenance.............................................................. 103 HYDRAULIC SYSTEM................................................................................ 105 HYDRAULIC/HYDROSTATIC SCHEMATICS............................................................ 111 HYDRAULIC SYSTEM INFORMATION................................................................ 123 Glossary Of Hydraulic / Hydrostatic Symbols............................................. 123 Troubleshooting......................................................................... 127 CYLINDER (LIFT)............................................................................. 129 Testing................................................................................. 129 Removal And Installation................................................................ 130 Parts Identification.................................................................... 134 Disassembly............................................................................. 135 Assembly................................................................................ 137 CYLINDER (TILT)............................................................................. 139 Testing................................................................................. 139 Removal And Installation................................................................ 140 Base End Pivot Pin Removal And Installation............................................. 142 Parts Identification.................................................................... 143 Disassembly............................................................................. 144 Assembly................................................................................ 146 CYLINDER (BOB-TACH)......................................................................... 149 Testing................................................................................. 149 Removal And Installation................................................................ 150 Parts Identification.................................................................... 151 Disassembly............................................................................. 152 Assembly................................................................................ 153 MAIN RELIEF VALVE (EARLY MODELS)............................................................ 157 Description............................................................................. 157 Testing................................................................................. 158 Adjusting............................................................................... 160 Removal And Installation................................................................ 161 MAIN RELIEF VALVE (LATER MODELS)............................................................ 163 Description............................................................................. 163 Testing................................................................................. 164 Main Relief Valve Adjustment............................................................ 166 Main Relief Valve Removal And Installation.............................................. 166 Auxiliary Relief Valve Adjustment....................................................... 167 Auxiliary Relief Valve Removal And Installation......................................... 168 HYDRAULIC CONTROL VALVE (STANDARD) (EARLY MODELS)........................................... 169 Description............................................................................. 169 Removal And Installation................................................................ 170 Mount Bracket Removal And Installation.................................................. 174 Identification Chart.................................................................... 175 Lift Load Check Valve Removal And Installation.......................................... 176 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................... 177 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................... 178 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........... 178 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........... 179 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............ 179 Port Relief Valve Removal And Installation.............................................. 180 Plug Removal And Installation........................................................... 181 Rubber Boot Removal And Installation.................................................... 182 End Cap Block Removal And Installation.................................................. 183 Lift Spool And Detent Removal And Installation.......................................... 184 Tilt Spool Removal And Installation..................................................... 194 Auxiliary Spool Removal And Installation................................................ 196 Auxiliary Solenoid Removal And Installation............................................. 198 Solenoid Removal And Installation....................................................... 199 Lock Valve Removal And Installation..................................................... 200 Lift Arm Bypass Orifice Removal And Installation........................................ 202 Main Relief Valve Removal And Installation.............................................. 202 Check Valve Removal And Installation.................................................... 203 HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS)........................................... 205 Description............................................................................. 205 Removal And Installation................................................................ 206 Mount Bracket Removal And Installation.................................................. 210 Identification Chart.................................................................... 211 Lift Load Check Valve Removal And Installation.......................................... 212 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................... 213 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................... 214 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........... 214 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........... 215 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............ 215 Port Relief Valve Removal And Installation.............................................. 216 Plug Removal And Installation........................................................... 218 Rubber Boot Removal And Installation.................................................... 219 End Cap Block Removal And Installation.................................................. 219 Lift Spool And Detent Removal And Installation.......................................... 220 Tilt Spool Removal And Installation..................................................... 228 Auxiliary Spool Removal And Installation................................................ 230 Auxiliary Solenoid Removal And Installation............................................. 231 Solenoid Removal And Installation....................................................... 232 Lock Valve Removal And Installation..................................................... 233 Lift Arm Bypass Orifice Removal And Installation........................................ 235 Main Relief Valve Removal And Installation.............................................. 235 Auxiliary Relief Valve Removal And Installation......................................... 236 Check Valve Removal And Installation.................................................... 236 HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLY MODELS)....................................... 239 Description............................................................................. 239 Removal And Installation................................................................ 239 Actuator Removal And Installation (In Loader)........................................... 244 Actuator Removal And Installation (Out Of Loader)....................................... 246 Identification Chart.................................................................... 249 Mount Bracket Removal And Installation.................................................. 250 Lift Load Check Valve Removal And Installation.......................................... 250 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................... 251 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................... 252 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........... 252 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........... 253 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............ 253 Port Relief Valve Removal And Installation.............................................. 254 Plug Removal And Installation........................................................... 255 End Cap Block Removal And Installation.................................................. 256 Lift Spool Removal And Installation..................................................... 256 Lift Spool Disassembly And Assembly..................................................... 258 Tilt Spool Removal And Installation..................................................... 260 Auxiliary Spool Removal And Installation................................................ 262 Auxiliary Solenoid Removal And Installation............................................. 263 Solenoid Removal And Installation....................................................... 264 Lock Valve Removal And Installation..................................................... 265 Lift Arm Bypass Orifice Removal And Installation........................................ 266 Main Relief Valve Removal And Installation.............................................. 266 Check Valve Removal And Installation.................................................... 267 HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS)....................................... 269 Description............................................................................. 269 Removal And Installation................................................................ 269 Actuator Removal And Installation (In Loader)........................................... 274 Actuator Removal And Installation (Out Of Loader)....................................... 275 Identification Chart.................................................................... 278 Mount Bracket Removal And Installation.................................................. 279 Lift Load Check Valve Removal And Installation.......................................... 279 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................... 280 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................... 281 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........... 281 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........... 282 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............ 282 Port Relief Valve Removal And Installation.............................................. 283 Plug Removal And Installation........................................................... 285 End Cap Block Removal And Installation.................................................. 286 Lift Spool Removal And Installation..................................................... 286 Lift Spool Disassembly And Assembly..................................................... 288 Tilt Spool Removal And Installation..................................................... 289 Auxiliary Spool Removal And Installation................................................ 291 Auxiliary Solenoid Removal And Installation............................................. 292 Solenoid Removal And Installation....................................................... 293 Lock Valve Removal And Installation..................................................... 294 Lift Arm Bypass Orifice Removal And Installation........................................ 296 Main Relief Valve Removal And Installation.............................................. 296 Auxiliary Relief Valve Removal And Installation......................................... 297 Check Valve Removal And Installation.................................................... 297 LIFT ARM BYPASS CONTROL VALVE............................................................... 299 Description............................................................................. 299 Testing................................................................................. 299 Removal And Installation................................................................ 300 Bracket Removal And Installation........................................................ 301 Disassembly And Assembly................................................................ 301 HYDRAULIC PUMP.............................................................................. 303 Description............................................................................. 303 Pump Test At Quick Couplers............................................................. 303 Direct Pump Test (Standard Section)..................................................... 304 Direct Pump Test (Charge Section)....................................................... 306 Removal And Installation................................................................ 308 Hydraulic Pump Startup.................................................................. 310 Parts Identification.................................................................... 311 Disassembly And Assembly................................................................ 312 HYDRAULIC PUMP (HIGH FLOW).................................................................. 313 Description............................................................................. 313 Pump Test At Quick Couplers............................................................. 313 Direct Pump Test (Standard Section)..................................................... 314 Direct Pump Test (Charge Section)....................................................... 315 Direct Pump Test (High Flow Section).................................................... 317 High Flow Relief Valve Adjustment....................................................... 319 High Flow Relief Valve Removal And Installation......................................... 320 Solenoid Removal And Installation....................................................... 321 Removal And Installation................................................................ 322 Hydraulic Pump Startup.................................................................. 324 Parts Identification.................................................................... 325 Disassembly And Assembly................................................................ 326 HYDRAULIC / HYDROSTATIC FILTERS............................................................. 327 Description............................................................................. 327 Housing Removal And Installation........................................................ 327 HYDRAULIC FLUID RESERVOIR................................................................... 329 Description............................................................................. 329 Removal And Installation................................................................ 329 Hydraulic Fluid Screen.................................................................. 330 OIL COOLER.................................................................................. 331 Description............................................................................. 331 Removal And Installation................................................................ 331 BUCKET POSITION VALVE....................................................................... 333 Description............................................................................. 333 Solenoid Removal And Installation....................................................... 333 Solenoid Testing........................................................................ 335 Removal And Installation................................................................ 335 Disassembly And Assembly................................................................ 337 REAR AUXILIARY DIVERTER VALVE............................................................... 339 Description............................................................................. 339 Solenoid Testing........................................................................ 339 Removal And Installation................................................................ 340 Disassembly And Assembly................................................................ 341 BOB-TACH (POWER) BLOCK...................................................................... 347 Description............................................................................. 347 Removal And Installation................................................................ 347 Disassembly And Assembly................................................................ 349 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK..................................................... 357 Description............................................................................. 357 Removal And Installation................................................................ 357 Disassembly And Assembly................................................................ 357 HYDROSTATIC SYSTEM.............................................................................. 359 HYDROSTATIC SYSTEM INFORMATION.............................................................. 361 Description............................................................................. 361 Troubleshooting......................................................................... 362 HYDROSTATIC DRIVE MOTOR..................................................................... 363 Description............................................................................. 363 Removing And Replacing Fluid............................................................ 363 Removal And Installation................................................................ 364 Parts Identification.................................................................... 366 Disassembly And Assembly................................................................ 368 HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N AN8T11001 - 11599)................................. 381 Description............................................................................. 381 Removing And Replacing Fluid............................................................ 381 Removal And Installation................................................................ 382 Parts Identification.................................................................... 384 Disassembly And Assembly................................................................ 386 HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N AN8T11600 & ABOVE and ATF711001 & Above)........... 399 Description............................................................................. 399 Removing And Replacing Fluid............................................................ 399 Removal And Installation................................................................ 400 Parts Identification.................................................................... 402 Disassembly And Assembly................................................................ 404 CHARGE PRESSURE............................................................................. 417 Description............................................................................. 417 Testing................................................................................. 417 Sender Removal And Installation......................................................... 419 Adjusting............................................................................... 420 HYDROSTATIC PUMP............................................................................ 423 Description............................................................................. 423 Removal And Installation................................................................ 424 Hydrostatic Pump Startup................................................................ 425 Replenishing / High Pressure Relief Valve Removal And Installation...................... 425 Parts Identification (Left Half)........................................................ 426 Parts Identification (Right Half)....................................................... 427 Disassembly............................................................................. 428 Assembly................................................................................ 435 HYDROSTATIC PUMP (SJC)...................................................................... 441 Description............................................................................. 441 Hydraulic Controller Removal And Installation........................................... 442 Removal And Installation................................................................ 444 Hydrostatic Pump Startup................................................................ 446 Parts Identification.................................................................... 447 High Pressure Relief And Bypass Valve................................................... 448 Charge Relief Valve..................................................................... 449 Disassembly............................................................................. 450 Inspection.............................................................................. 459 Assembly................................................................................ 463 Mechanical Neutral Adjustment........................................................... 473 Hydraulic Controller Neutral Adjustment................................................. 476 DRIVE BELT.................................................................................. 479 Belt Adjustment......................................................................... 479 Stop Adjustment......................................................................... 479 Belt Replacement........................................................................ 479 Tensioner Pulley Removal And Installation............................................... 481 Tensioner Pulley Disassembly And Assembly............................................... 481 TWO-SPEED / BRAKE VALVE (S/N AN8T11001-11599)............................................... 483 Description............................................................................. 483 Valve Block Removal And Installation.................................................... 484 Valve Block Disassembly And Assembly.................................................... 486 TWO-SPEED / BRAKE VALVE (S/N AN8T11600 & ABOVE) and (ATF711001 & Above)..................... 489 Description............................................................................. 489 Valve Block Removal And Installation.................................................... 490 Valve Block Disassembly And Assembly.................................................... 492 DRAIN MANIFOLD.............................................................................. 495 Description............................................................................. 495 Drain Manifold Removal And Installation................................................. 495 DRIVE SYSTEM.................................................................................... 497 BRAKE....................................................................................... 499 Description............................................................................. 499 Block Removal And Installation.......................................................... 499 Block Disassembly And Assembly.......................................................... 500 BRAKE (TWO-SPEED)........................................................................... 503 Description............................................................................. 503 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED).............................................. 505 Description............................................................................. 505 Checking Tension........................................................................ 506 Adjusting Tension....................................................................... 507 Track Removal And Installation.......................................................... 508 Idler (Front) Removal And Installation.................................................. 510 Track Tensioner Disassembly And Assembly................................................ 513 Idler (Rear) Removal And Installation................................................... 515 Roller Removal And Installation......................................................... 515 Sprocket Removal And Installation (Single Speed)........................................ 516 Sprocket Removal And Installation (Two Speed)........................................... 516 Track Housing Removal And Installation.................................................. 517 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION).......................................... 519 Description............................................................................. 519 Checking Tension........................................................................ 520 Adjusting Tension....................................................................... 521 Track Removal And Installation.......................................................... 522 Idler (Front) Removal And Installation.................................................. 524 Track Tensioner Disassembly And Assembly................................................ 527 Idler (Rear) Removal And Installation................................................... 529 Roller Removal And Installation......................................................... 529 Leaf Spring Removal And Installation.................................................... 530 Sprocket Removal And Installation....................................................... 531 Sprocket Removal And Installation (Two Speed)........................................... 531 Track Housing Removal And Installation.................................................. 532 TRACK MAINTENANCE........................................................................... 533 Track Damage Identification............................................................. 533 MAINFRAME....................................................................................... 545 SEAT BAR.................................................................................... 549 Description............................................................................. 549 Removal And Installation................................................................ 549 Disassembly And Assembly................................................................ 550 Compression Spring Disassembly And Assembly............................................. 551 OPERATOR CAB................................................................................ 553 Gas Spring Removal And Installation..................................................... 553 Gas Spring Bracket Disassembly And Assembly............................................. 554 Removal And Installation................................................................ 554 OPERATOR SEAT (SUSPENSION).................................................................. 557 Removal And Installation................................................................ 557 Slide Rail Removal And Installation..................................................... 557 Seat Belt Removal And Installation...................................................... 558 Lower Cushion Removal................................................................... 558 Lower Cushion Installation.............................................................. 559 Back Cushion Removal And Installation................................................... 559 Shock Removal And Installation.......................................................... 560 3-Point Seat Belt Removal And Installation.............................................. 560 BOB-TACH (HAND LEVER)....................................................................... 563 Description............................................................................. 563 Removal And Installation................................................................ 563 Lever And Wedge Disassembly And Assembly................................................ 565 Pivot Pin Bushing And Seal Removal And Installation..................................... 567 BOB-TACH (POWER)............................................................................ 569 Description............................................................................. 569 Removal And Installation................................................................ 569 Lever And Wedge Disassembly And Assembly................................................ 572 Pivot Pin Bushing And Seal Removal And Installation..................................... 573 LIFT ARMS................................................................................... 575 Stabilizer Bar Removal And Installation................................................. 575 Link Removal And Installation........................................................... 576 Removal And Installation................................................................ 577 REAR GRILLE................................................................................. 581 Removing................................................................................ 581 Installing.............................................................................. 581 REAR DOOR (TAILGATE)........................................................................ 583 Removal And Installation................................................................ 583 Striker Removal And Installation........................................................ 584 Striker Disassembly And Assembly........................................................ 584 Striker (Adjusting)..................................................................... 584 Latch Removal And Installation (Early Models)........................................... 585 Latch Removal And Installation (Later Models)........................................... 586 FUEL TANK................................................................................... 587 Removal And Installation................................................................ 587 Fuel Level Sender Removal And Installation.............................................. 589 Fuel Fill Screen Removal And Installation............................................... 589 CONTROL PEDALS AND LINKAGES................................................................. 591 Description............................................................................. 591 Pedal Removal And Installation.......................................................... 591 Linkage Removal And Installation........................................................ 592 Pedal (Adjusting)....................................................................... 593 Floor Pan Removal And Installation...................................................... 594 CONTROL PEDALS AND LINKAGES (ACS)........................................................... 595 Description............................................................................. 595 Pedal Removal And Installation.......................................................... 595 Linkage Removal And Installation........................................................ 596 Pedal (Adjusting)....................................................................... 596 Floor Pan Removal And Installation...................................................... 597 CONTROL PANEL............................................................................... 599 Description............................................................................. 599 Removal And Installation................................................................ 600 Disassembly And Assembly................................................................ 601 Linkage Removal And Installation........................................................ 603 Pintle Arm Disassembly And Assembly..................................................... 607 Linkage Neutral (Adjusting)............................................................. 608 Linkage Travel (Adjusting).............................................................. 612 Shock Removal And Installation.......................................................... 616 CONTROL PANEL (SJC)......................................................................... 617 Description............................................................................. 617 Removal And Installation................................................................ 617 CONTROL HANDLE / LEVER...................................................................... 619 Description............................................................................. 619 Lever Removal And Installation.......................................................... 619 Boot Removal And Installation........................................................... 619 CONTROL HANDLE / LEVER (ACS)................................................................ 621 Description............................................................................. 621 Handle Sensor Removal And Installation.................................................. 621 Handle Removal And Installation......................................................... 624 Handle Disassembly And Assembly......................................................... 625 Lever Removal And Installation.......................................................... 625 Boot Removal And Installation........................................................... 626 CONTROL HANDLE / LEVER (SJC)................................................................ 627 Description............................................................................. 627 Joystick Testing........................................................................ 627 Joystick Removal And Installation....................................................... 628 ACCESS PANEL (INSIDE)....................................................................... 629 Removal And Installation (Left)......................................................... 629 Removal And Installation (Right)........................................................ 629 ACCESS PANEL (INSIDE) (SJC)................................................................. 631 Removal And Installation (Left)......................................................... 631 Removal And Installation (Right)........................................................ 631 WINDOW (REAR)............................................................................... 633 Removal And Installation................................................................ 633 Disassembly And Assembly................................................................ 633 WINDOW (TOP)................................................................................ 635 Removal And Installation................................................................ 635 WINDOW (SIDE)............................................................................... 637 Removal And Installation................................................................ 637 CAB DOOR.................................................................................... 639 Description............................................................................. 639 Removal And Installation................................................................ 639 Disassembly And Assembly................................................................ 640 Aligning................................................................................ 641 Adjusting............................................................................... 642 Checking Operation...................................................................... 642 ARMREST..................................................................................... 643 Description............................................................................. 643 Removal And Installation................................................................ 644 Disassembly And Assembly................................................................ 645 LEFT SIDE LOWER PANEL....................................................................... 647 Removal And Installation................................................................ 647 Disassembly And Assembly................................................................ 649 RIGHT SIDE LOWER PANEL...................................................................... 651 Removal And Installation................................................................ 651 Disassembly And Assembly................................................................ 652 HEADLINER................................................................................... 655 Removal And Installation................................................................ 655 ELECTRICAL SYSTEM AND ANALYSIS.................................................................. 657 ELECTRICAL SCHEMATICS....................................................................... 661 ELECTRICAL SYSTEM INFORMATION............................................................... 703 Glossary Of Electrical Symbols.......................................................... 703 Standard Cab Harness Connectors......................................................... 706 Deluxe Cab Harness Connectors........................................................... 707 Mainframe Harness Connectors............................................................ 708 Engine Harness Connectors............................................................... 709 Description............................................................................. 710 Troubleshooting......................................................................... 711 Fuse And Relay Location / Identification................................................ 712 Solenoid Testing........................................................................ 715 BATTERY..................................................................................... 717 Removal And Installation................................................................ 717 Servicing............................................................................... 718 Using A Booster Battery (Jump Starting)................................................. 719 ALTERNATOR.................................................................................. 721 Belt Adjustment......................................................................... 721 Belt Replacement........................................................................ 721 Charging System Inspection.............................................................. 722 Alternator Voltage Testing.............................................................. 723 Low Voltage Testing..................................................................... 723 High Voltage Testing.................................................................... 724 Removal And Installation................................................................ 725 Parts Identification.................................................................... 727 STARTER..................................................................................... 729 Testing................................................................................. 729 Removal And Installation................................................................ 729 Parts Identification.................................................................... 730 INSTRUMENT PANELS........................................................................... 731 Left Panel.............................................................................. 731 Display Screen.......................................................................... 733 Right Panel (Standard Key Panel)........................................................ 734 Right Panel (Keyless Start Panel)....................................................... 735 Right Panel (Deluxe Instrumentation Panel).............................................. 736 Left Switch Panel....................................................................... 738 Right Switch Panel...................................................................... 738 Left Side Lower Panel................................................................... 739 Right Side Lower Panel.................................................................. 739 Left Panel Removal And Installation..................................................... 740 Right Panel (Standard Key Panel) Removal And Installation............................... 740 Right Panel (Keyless Start Panel) Removal And Installation.............................. 741 Right Panel (Deluxe Instrumentation Panel) Removal And Installation..................... 741 Key Switch Disassembly And Assembly..................................................... 742 Alarm Disassembly And Assembly.......................................................... 742 Left Switch Panel Removal And Installation.............................................. 743 Right Switch Panel Removal And Installation............................................. 743 LIGHTS...................................................................................... 745 Front Removal And Installation.......................................................... 745 Rear Removal And Installation........................................................... 746 Cab Light Removal And Installation...................................................... 746 BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY).................................................. 747 Description............................................................................. 747 Connector Identification................................................................ 748 Removal And Installation................................................................ 754 BOBCAT CONTROLLER (ACS)..................................................................... 755 Description............................................................................. 755 Connector And Wire Identification....................................................... 756 Removal And Installation................................................................ 757 BOBCAT CONTROLLER (SJC) (DRIVE)............................................................. 759 Description............................................................................. 759 Connector Identification................................................................ 760 Removal And Installation................................................................ 762 ENGINE CONTROL UNIT (ECU)................................................................... 763 Description............................................................................. 763 Cleaning................................................................................ 764 Removal And Installation................................................................ 765 DIAGNOSTIC SERVICE CODES.................................................................... 767 Viewing Service Codes................................................................... 767 Service Codes List...................................................................... 768 DIAGMASTER DIAGNOSTIC TROUBLE CODES (DCT)................................................... 775 Viewing Trouble Codes................................................................... 775 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..................................................... 777 Description............................................................................. 777 Operation............................................................................... 777 Inspecting The BICS™ (Engine STOPPED - Key ON).......................................... 778 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON).... 778 Inspecting The Seat Bar Sensor (Engine RUNNING)......................................... 778 Inspecting The Traction Lock (Engine RUNNING)........................................... 778 Inspecting The Lift Arm Bypass Control.................................................. 778 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)........................ 778 Troubleshooting......................................................................... 779 SEAT BAR SENSOR............................................................................. 781 Description............................................................................. 781 Troubleshooting......................................................................... 781 Testing................................................................................. 782 Removal And Installation................................................................ 783 Bobcat Interlock Control System (BICS™) Circuit Test.................................... 786 TRACTION LOCK............................................................................... 789 Description............................................................................. 789 Troubleshooting......................................................................... 790 Inspecting.............................................................................. 791 CONTROL SYSTEM (ACS)........................................................................ 793 Description............................................................................. 793 Troubleshooting......................................................................... 794 Handle Sensor Connector Disassembly And Assembly........................................ 795 Switch Handle Removal................................................................... 796 Switch Handle Installation.............................................................. 798 Actuator Connector Disassembly And Assembly............................................. 801 Handle Lock Solenoid Removal And Installation........................................... 802 Handle Lock Solenoid Disassembly And Assembly........................................... 802 Foot Sensor Removal And Installation.................................................... 803 Foot Sensor Disassembly And Assembly.................................................... 804 Foot Sensor Lock Solenoid Removal And Installation...................................... 804 ELECTRICAL / HYDRAULIC CONTROLS............................................................. 805 Identification Chart.................................................................... 805 Description............................................................................. 806 Identification Chart ACD Group 0........................................................ 807 Identification Chart ACD Group 1........................................................ 808 Identification Chart ACD Group 2........................................................ 809 Identification Chart ACD Group 3........................................................ 810 ELECTRICAL / HYDRAULIC CONTROLS (ACS)....................................................... 811 Identification Chart.................................................................... 811 Description............................................................................. 812 Identification Chart ACD Group 0........................................................ 813 Identification Chart ACD Group 1........................................................ 814 Identification Chart ACD Group 2........................................................ 815 Identification Chart ACD Group 3........................................................ 816 ELECTRICAL / HYDRAULIC CONTROLS (SJC)....................................................... 817 Identification Chart.................................................................... 817 Description............................................................................. 818 Identification Chart ACD Group 0........................................................ 819 Identification Chart ACD Group 1........................................................ 820 Identification Chart ACD Group 2........................................................ 821 Identification Chart ACD Group 3........................................................ 822 SERVICE PC (LAPTOP COMPUTER)................................................................ 823 Connecting Remote Start Tool............................................................ 823 Connecting Remote Start Tool (Service Tool)............................................. 823 Connecting Diagmaster (Service Tool).................................................... 824 Connecting Remote Parked Regeneration Kit............................................... 824 CALIBRATION................................................................................. 825 Description............................................................................. 825 Actuator Testing........................................................................ 825 Lift And Tilt Calibration (SJC)......................................................... 828 Hydrostatic Pump Calibration (SJC)...................................................... 830 Lift And Tilt Calibration (ACS)......................................................... 835 STEERING DRIFT COMPENSATION................................................................. 837 Description............................................................................. 837 Operation............................................................................... 837 CONTROL PANEL SETUP......................................................................... 839 Right Panel Setup (Deluxe Instrumentation Panel)........................................ 839 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)............................................... 843 Password Description.................................................................... 843 Changing The Owner Password............................................................. 843 Changing The User Passwords............................................................. 844 Password Lockout Feature................................................................ 844 PASSWORD SETUP (KEYLESS START PANEL)........................................................ 845 Password Description.................................................................... 845 Changing The Owner Password............................................................. 845 Password Lockout Feature................................................................ 845 MAINTENANCE CLOCK........................................................................... 847 Description............................................................................. 847 Setup................................................................................... 848 Reset................................................................................... 851 BACK-UP ALARM SYSTEM........................................................................ 853 Description............................................................................. 853 Inspecting.............................................................................. 853 Adjusting Switch Position............................................................... 854 Troubleshooting (Standard And ACS)...................................................... 855 Troubleshooting (Joystick).............................................................. 856 Alarm Removal And Installation.......................................................... 857 Switch Removal And Installation......................................................... 857 FRONT HORN.................................................................................. 859 Removal And Installation................................................................ 859 Troubleshooting......................................................................... 860 Troubleshooting (Joystick).............................................................. 861 ENGINE SERVICE.................................................................................. 863 ENGINE INFORMATION.......................................................................... 867 Description............................................................................. 867 Specifications.......................................................................... 868 Sensor Location......................................................................... 871 Torque Values........................................................................... 874 Troubleshooting......................................................................... 875 Engine Removal And Installation......................................................... 876 Engine Mount Replacement................................................................ 889 Compression - Testing................................................................... 891 ENGINE SPEED CONTROL (HAND)................................................................. 895 Removal And Installation................................................................ 895 ENGINE SPEED CONTROL (FOOT)................................................................. 897 Removal And Installation................................................................ 897 Disassembly And Assembly................................................................ 898 DIESEL PARTICULATE FILTER (DPF) SYSTEM...................................................... 901 Description............................................................................. 901 Removal And Installation................................................................ 902 DPF Regeneration........................................................................ 905 DPF Regeneration Table.................................................................. 905 Operation (Standard Switch)............................................................. 906 Operation (Optional Inhibit Switch Kit)................................................. 907 Operation (Optional Remote Parked Regeneration Kit)..................................... 908 Remote Parked Regeneration (Level 3).................................................... 908 DPF Service Regeneration (Level 4)...................................................... 910 DPF Cleaning (Level 5).................................................................. 913 AIR CLEANER................................................................................. 915 Housing Removal And Installation........................................................ 915 ENGINE COOLING SYSTEM....................................................................... 917 Radiator Removal And Installation....................................................... 917 Hydraulic Fan Description............................................................... 918 Fan Duct Removal And Installation....................................................... 919 Hydraulic Fan Motor Assembly Removal And Installation................................... 919 Hydraulic Fan Motor Removal And Installation............................................ 920 Hydraulic Fan Motor Disassembly And Assembly............................................ 921 Blower Housing Removal And Installation................................................. 923 Water Pump Removal And Installation..................................................... 923 Water Pump Disassembly And Assembly..................................................... 924 Thermostat Housing Removal And Installation............................................. 924 Thermostat - Testing.................................................................... 925 LUBRICATION SYSTEM.......................................................................... 927 Oil Pan Removal And Installation........................................................ 927 Oil Pump Removal And Installation....................................................... 928 Oil Pump Inspection..................................................................... 928 Oil Filter Cooler Removal And Installation.............................................. 930 Engine Oil Pressure - Testing........................................................... 931 Crankcase Ventilation Filter Removal And Installation................................... 932 FUEL SYSTEM................................................................................. 933 Supply Pump Removal..................................................................... 933 Supply Pump Installation................................................................ 936 Supply Pump Difference Learning......................................................... 938 Fuel Rail Assembly Removal And Installation............................................. 940 Supply Pump - Timing.................................................................... 941 Fuel Injector Removal And Installation.................................................. 942 Injector Correction..................................................................... 946 CYLINDER HEAD............................................................................... 947 Intake Air Heater - Testing............................................................. 947 Intake Air Heater Removal And Installation.............................................. 947 Valve Clearance Adjustment.............................................................. 948 Valve Timing - Checking................................................................. 950 Cylinder Head Removal And Installation.................................................. 951 Cylinder Head Disassembly And Assembly.................................................. 953 Cylinder Head - Servicing............................................................... 954 Cylinder Head Top Clearance............................................................. 954 Valve Guide - Servicing................................................................. 955 Reconditioning The Valve And Valve Seat................................................. 957 Valve Spring............................................................................ 959 Valve Tappets........................................................................... 960 Rocker Arm And Shaft - Measuring........................................................ 961 Push Rod Alignment - Measuring.......................................................... 961 CRANKSHAFT AND PISTONS...................................................................... 963 Piston And Connecting Rod Removal And Installation...................................... 963 Piston And Connecting Rod - Servicing................................................... 965 Cylinder Bore - Measuring............................................................... 969 Connecting Rod Alignment................................................................ 970 Crankshaft Gear Removal And Installation................................................ 970 Crankshaft And Bearings Removal......................................................... 971 Crankshaft And Bearings Installation.................................................... 973 Crankshaft And Bearings - Servicing..................................................... 975 CRANKSHAFT POSITION SENSOR.................................................................. 981 Description............................................................................. 981 Removal And Installation................................................................ 981 Adjusting............................................................................... 982 CAMSHAFT AND TIMING GEARS................................................................... 985 Timing Gearcase Cover Removal And Installation.......................................... 985 Timing Gears Backlash - Measuring....................................................... 986 Idler Gear And Camshaft Removal And Installation........................................ 986 Camshaft - Servicing.................................................................... 987 Idler Gear And Shaft - Servicing........................................................ 989 TURBOCHARGER................................................................................ 993 Description............................................................................. 993 Removal And Installation................................................................ 994 Testing................................................................................. 996 EGR Cooler Testing...................................................................... 997 FLYWHEEL AND HOUSING........................................................................ 999 Flywheel Removal And Installation....................................................... 999 Ring Gear Removal And Installation...................................................... 999 Housing Removal And Installation........................................................1000 EXHAUST GAS RECIRCULATION (EGR) SYSTEM......................................................1001 Description.............................................................................1001 Testing.................................................................................1002 Removal And Installation................................................................1004 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)................................................1005 AIR CONDITIONING SYSTEM FLOW................................................................1007 Description.............................................................................1007 Chart...................................................................................1008 Components..............................................................................1009 Safety Equipment........................................................................1012 REGULAR MAINTENANCE.........................................................................1013 Filters.................................................................................1013 Compressor Drive Belt Adjustment........................................................1014 Compressor Drive Belt Replacement.......................................................1014 Condenser...............................................................................1014 Air Conditioning Lubrication............................................................1014 Air Conditioning Service Chart..........................................................1015 Evaporator / Heater Coil................................................................1016 TROUBLESHOOTING.............................................................................1017 Blower Motor Does Not Operate...........................................................1017 Blower Motor Operates Normally, But Air Flow Is Insufficient............................1017 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............1017 The Compressor Does Not Operate At All, Or Operates Improperly..........................1017 Gauge Pressure Related Troubleshooting..................................................1018 Troubleshooting Tree....................................................................1020 Temperature / Pressure Chart............................................................1023 Poor A/C Performance....................................................................1025 HVAC Repair And Leaks...................................................................1026 Electrical System.......................................................................1027 Engine Coolant Bypassing The Heater Valve...............................................1033 Heater Valve Not Opening Or Closing.....................................................1034 SYSTEM CHARGING AND RECLAMATION.............................................................1037 Refrigerant Identification..............................................................1037 Reclamation And Charging With Recovery / Charging Unit..................................1038 COMPRESSOR..................................................................................1041 Removal And Installation................................................................1041 Oil.....................................................................................1043 Oil Check...............................................................................1044 CONDENSER...................................................................................1045 Removal And Installation................................................................1045 RECEIVER / DRIER............................................................................1047 Receiver / Drier Removal And Installation...............................................1047 Pressure Relief Valve Removal And Installation..........................................1048 Pressure Switch Removal And Installation................................................1049 Schrader® Valve Removal And Installation................................................1050 EVAPORATOR / HEATER UNIT....................................................................1051 Removal And Installation................................................................1051 THERMOSTAT..................................................................................1053 Description.............................................................................1053 Removal And Installation................................................................1054 EXPANSION VALVE.............................................................................1055 Removal And Installation................................................................1055 EVAPORATOR COIL.............................................................................1057 Removal And Installation................................................................1057 HEATER COIL.................................................................................1059 Removal And Installation................................................................1059 BLOWER FAN..................................................................................1061 Removal And Installation................................................................1061 Disassembly And Assembly................................................................1061 HEATER VALVE................................................................................1065 Removal And Installation................................................................1065 EVAPORATOR / HEATER COVER...................................................................1067 Removing................................................................................1067 Installing..............................................................................1067 SPECIFICATIONS..................................................................................1069 (T770) LOADER SPECIFICATIONS................................................................1071 Machine Dimensions......................................................................1071 Performance.............................................................................1072 Engine..................................................................................1072 Drive System............................................................................1073 Controls................................................................................1073 Hydraulic System........................................................................1074 Electrical System.......................................................................1075 Capacities..............................................................................1075 Tracks..................................................................................1076 Ground Pressure.........................................................................1076 TECHINCAL SERVICE GUIDE SPECIFICATIONS......................................................1077 Engine..................................................................................1077 Engine Torques..........................................................................1077 Cooling System..........................................................................1077 Loader Torques..........................................................................1078 Hydraulic / Hydrostatic System..........................................................1078 Fuel Consumption........................................................................1078 TORQUE SPECIFICATIONS FOR BOLTS.............................................................1079 Torque For General SAE Bolts............................................................1079 Torque For General Metric Bolts.........................................................1080 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................1081 Straight Thread O-ring Fitting..........................................................1081 Flare Fitting...........................................................................1082 Tube lines And Hoses....................................................................1082 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................1083 Specifications..........................................................................1083 CONVERSIONS.................................................................................1085 Decimal And Millimeter Equivalent Chart.................................................1085 U.S. To Metric Conversion Chart.........................................................1085 SERVICE TOOLS REQUIRED......................................................................1087 Remote Start Tools......................................................................1087 Hydraulic Tools.........................................................................1088 Mainframe And Drive Tools...............................................................1090 Electrical Tools........................................................................1091 Engine Tools............................................................................1091 HVAC Tools..............................................................................1096 ALPHABETICAL INDEX..............................................................................1097
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