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Bobcat T770 Compact Track Loader Service Manual SN AUYB11001 & Above – PDF DOWNLOAD
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Bobcat T770 Compact Track Loader Service Manual SN AUYB11001 & Above – PDF DOWNLOAD
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Description
Bobcat T770 Compact Track Loader Service Manual SN AUYB11001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat T770 Compact Track Loader Service Manual SN AUYB11001 & Above – PDF DOWNLOAD
Language : English
Pages : 982
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T770 Compact Track Loader Service Manual SN AUYB11001 & Above – PDF DOWNLOAD
FOREWORD:
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS (Including side screens) is in good condition and is not modified.
2. Check that ROPS mounting hardware is tightened and is Bobcat approved.
3. The seat belt must be correctly installed, functional and in good condition.
4. The seat bar must be correctly adjusted, clean and lubricated.
5. Check lift arm support device, replace if damaged.
6. Machine signs (decals) must be legible and in the correct location.
7. Steering levers, hand controls and foot pedals must return to neutral (as applicable).
8. Check for correct function of the work lights.
9. The parking brake must function correctly.
10. Enclosure door latches must open and close freely.
11. Bob-Tach wedges and linkages must function correctly and be in good condition.
12. Safety treads must be in good condition.
13. Check for correct function of indicator lamps.
14. Check hydraulic fluid level, engine oil level and fuel supply.
15. Inspect for fuel, oil or hydraulic fluid leaks.
SAFETY INSTRUCTIONS:
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
• The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
• The AEM Safety Manual delivered with the machine gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
TABLE OF CONTENTS:
Bobcat T770 Compact Track Loader Service Manual SN AUYB11001 & Above – 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............................................................. 21 Procedure............................................................................... 21 LIFT ARM SUPPORT DEVICE..................................................................... 23 Installing.............................................................................. 23 Removing................................................................................ 24 OPERATOR CAB................................................................................ 25 Description............................................................................. 25 Raising................................................................................. 26 Lowering................................................................................ 27 Cab Door Sensor......................................................................... 28 Special Applications Kit................................................................ 28 Special Applications Kit Inspection And Maintenance..................................... 28 Forestry Door And Window Kit............................................................ 29 Forestry Door And Window Kit Inspection And Maintenance................................. 29 TRANSPORTING THE LOADER ON A TRAILER........................................................ 31 Loading And Unloading................................................................... 31 Fastening............................................................................... 31 TOWING THE LOADER........................................................................... 33 Procedure............................................................................... 33 REMOTE START TOOL KIT - MEL1563............................................................. 35 Remote Start Tool - MEL1563............................................................. 35 Service Tool Harness Communicator - MEL1566............................................. 37 Remote Start Procedure.................................................................. 37 REMOTE START TOOL (SERVICE TOOL) KIT - 7003031.............................................. 41 Description............................................................................. 41 Remote Start Tool (Service Tool) - 7003030.............................................. 42 Loader Service Tool Harness - 6689747................................................... 43 Computer Service Tool Harness - 6689746................................................. 44 Remote Start Procedure.................................................................. 45 SERVICE SCHEDULE............................................................................ 49 Chart................................................................................... 49 AIR CLEANER SERVICE......................................................................... 51 Replacing Filter Elements............................................................... 51 ENGINE COOLING SYSTEM....................................................................... 53 Maintenance Platform.................................................................... 53 Cleaning................................................................................ 53 Checking Level.......................................................................... 55 Removing And Replacing Coolant.......................................................... 56 FUEL SYSTEM................................................................................. 57 Fuel Specifications..................................................................... 57 Biodiesel Blend Fuel.................................................................... 57 Filling The Fuel Tank................................................................... 58 Fuel Filter............................................................................. 59 Removing Air From The Fuel System....................................................... 59 ENGINE LUBRICATION SYSTEM................................................................... 61 Checking And Adding Engine Oil.......................................................... 61 Engine Oil Chart........................................................................ 61 Removing And Replacing Oil And Filter................................................... 62 HYDRAULIC / HYDROSTATIC SYSTEM.............................................................. 63 Checking And Adding Fluid............................................................... 63 Hydraulic / Hydrostatic Fluid Chart..................................................... 63 Removing And Replacing Hydraulic Fluid.................................................. 64 Removing And Replacing Hydraulic / Hydrostatic Filter................................... 66 Removing And Replacing Hydraulic Charge Filter.......................................... 67 Breather Cap............................................................................ 68 BOB-TACH (HAND LEVER)....................................................................... 69 Inspection And Maintenance.............................................................. 69 BOB-TACH (POWER)............................................................................ 71 Inspection And Maintenance.............................................................. 71 LUBRICATING THE LOADER...................................................................... 73 Lubrication Locations................................................................... 73 SPARK ARRESTER MUFFLER...................................................................... 77 Cleaning Procedure...................................................................... 77 PIVOT PINS.................................................................................. 79 Inspection And Maintenance.............................................................. 79 LOADER STORAGE AND RETURN TO SERVICE........................................................ 81 Storage................................................................................. 81 Return To Service....................................................................... 81 STOPPING THE ENGINE AND LEAVING THE LOADER.................................................. 83 Procedure............................................................................... 83 EMERGENCY EXIT.............................................................................. 85 External Access......................................................................... 85 Rear Window............................................................................. 85 Front Door.............................................................................. 85 SEAT BELT................................................................................... 87 Inspection And Maintenance.............................................................. 87 HYDRAULIC SYSTEM................................................................................ 89 HYDRAULIC / HYDROSTATIC SCHEMATICS.......................................................... 93 HYDRAULIC SYSTEM INFORMATION................................................................105 Glossary Of Hydraulic / Hydrostatic Symbols.............................................105 Troubleshooting.........................................................................109 CYLINDER (LIFT).............................................................................111 Testing.................................................................................111 Removal And Installation................................................................112 Parts Identification....................................................................116 Disassembly.............................................................................117 Assembly................................................................................118 CYLINDER (TILT).............................................................................121 Testing.................................................................................121 Removal And Installation................................................................122 Base End Pivot Pin Removal And Installation.............................................124 Parts Identification....................................................................125 Disassembly.............................................................................126 Assembly................................................................................128 CYLINDER (BOB-TACH).........................................................................131 Testing.................................................................................131 Removal And Installation................................................................132 Parts Identification....................................................................133 Disassembly.............................................................................134 Assembly................................................................................135 MAIN RELIEF VALVE...........................................................................139 Description.............................................................................139 Testing.................................................................................140 Adjusting...............................................................................142 Removal And Installation................................................................143 HYDRAULIC CONTROL VALVE (STANDARD)..........................................................145 Description.............................................................................145 Removal And Installation................................................................146 Mount Bracket Removal And Installation..................................................149 Identification Chart....................................................................150 Lift Load Check Valve Removal And Installation..........................................151 Load Check Valve Removal And Installation (Tilt And Auxiliary)..........................152 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................153 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........153 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........154 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............154 Port Relief Valve Removal And Installation..............................................155 Plug Removal And Installation...........................................................156 Rubber Boot Removal And Installation....................................................157 End Cap Block Removal And Installation..................................................158 Lift Spool And Detent Removal And Installation..........................................159 Tilt Spool Removal And Installation.....................................................169 Auxiliary Spool Removal And Installation................................................171 Auxiliary Solenoid Removal And Installation.............................................173 Solenoid Removal And Installation.......................................................174 Lock Valve Removal And Installation.....................................................175 Lift Arm Bypass Orifice Removal And Installation........................................177 Main Relief Valve Removal And Installation..............................................177 Check Valve Removal And Installation....................................................178 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)......................................................179 Description.............................................................................179 Removal And Installation................................................................179 Actuator Removal And Installation (In Loader)...........................................183 Actuator Removal And Installation (Out Of Loader).......................................185 Identification Chart....................................................................188 Mount Bracket Removal And Installation..................................................189 Lift Load Check Valve Removal And Installation..........................................189 Load Check Valve Removal And Installation (Tilt And Auxiliary)..........................190 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................191 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........191 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........192 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............192 Port Relief Valve Removal And Installation..............................................193 Plug Removal And Installation...........................................................194 End Cap Block Removal And Installation..................................................195 Lift Spool Removal And Installation.....................................................195 Lift Spool Disassembly And Assembly.....................................................197 Tilt Spool Removal And Installation.....................................................199 Auxiliary Spool Removal And Installation................................................201 Auxiliary Solenoid Removal And Installation.............................................202 Solenoid Removal And Installation.......................................................203 Lock Valve Removal And Installation.....................................................204 Lift Arm Bypass Orifice Removal And Installation........................................205 Main Relief Valve Removal And Installation..............................................205 Check Valve Removal And Installation....................................................206 LIFT ARM BYPASS CONTROL VALVE...............................................................207 Description.............................................................................207 Testing.................................................................................207 Removal And Installation................................................................208 Bracket Removal And Installation........................................................209 Disassembly And Assembly................................................................209 HYDRAULIC PUMP..............................................................................211 Description.............................................................................211 Pump Test At Quick Couplers.............................................................211 Direct Pump Test (Standard Section).....................................................212 Direct Pump Test (Charge Section).......................................................214 Removal And Installation................................................................216 Hydraulic Pump Startup..................................................................218 Parts Identification....................................................................219 Disassembly And Assembly................................................................220 HYDRAULIC PUMP (HIGH FLOW)..................................................................221 Description.............................................................................221 Pump Test At Quick Couplers.............................................................221 Direct Pump Test (Standard Section).....................................................222 Direct Pump Test (Charge Section).......................................................223 Direct Pump Test (High Flow Section)....................................................225 High Flow Relief Valve Adjustment.......................................................227 High Flow Relief Valve Removal And Installation.........................................228 Solenoid Removal And Installation.......................................................229 Removal And Installation................................................................230 Hydraulic Pump Startup..................................................................232 Parts Identification....................................................................233 Disassembly And Assembly................................................................234 HYDRAULIC / HYDROSTATIC FILTERS.............................................................235 Description.............................................................................235 Housing Removal And Installation........................................................235 HYDRAULIC FLUID RESERVOIR...................................................................237 Description.............................................................................237 Removal And Installation................................................................237 Hydraulic Fluid Screen..................................................................238 OIL COOLER..................................................................................239 Description.............................................................................239 Removal And Installation................................................................240 BUCKET POSITION VALVE.......................................................................241 Description.............................................................................241 Solenoid Removal And Installation.......................................................242 Solenoid Testing........................................................................243 Removal And Installation................................................................243 Disassembly And Assembly................................................................245 REAR AUXILIARY DIVERTER VALVE...............................................................247 Description.............................................................................247 Solenoid Testing........................................................................247 Removal And Installation................................................................248 Disassembly And Assembly................................................................249 BOB-TACH (POWER) BLOCK......................................................................255 Description.............................................................................255 Removal And Installation................................................................255 Disassembly And Assembly................................................................257 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.....................................................267 Description.............................................................................267 Removal And Installation................................................................267 Disassembly And Assembly................................................................268 HYDROSTATIC SYSTEM..............................................................................271 HYDROSTATIC SYSTEM INFORMATION..............................................................273 Description.............................................................................273 Troubleshooting.........................................................................274 HYDROSTATIC DRIVE MOTOR.....................................................................275 Description.............................................................................275 Removing And Replacing Oil..............................................................275 Removal And Installation................................................................276 Parts Identification....................................................................278 Disassembly And Assembly................................................................280 HYDROSTATIC DRIVE MOTOR (TWO-SPEED).........................................................293 Description.............................................................................293 Removing And Replacing Oil..............................................................293 Removal And Installation................................................................294 Parts Identification....................................................................296 Disassembly And Assembly................................................................298 CHARGE PRESSURE.............................................................................311 Description.............................................................................311 Testing.................................................................................311 Sender Removal And Installation.........................................................313 Adjusting...............................................................................314 HYDROSTATIC PUMP............................................................................317 Description.............................................................................317 Removal And Installation................................................................318 Hydrostatic Pump Startup................................................................319 Replenishing / High Pressure Relief Valve Removal And Installation......................320 Parts Identification (Left Half)........................................................321 Parts Identification (Right Half).......................................................322 Disassembly.............................................................................323 Assembly................................................................................330 HYDROSTATIC PUMP (SJC)......................................................................337 Description.............................................................................337 Hydraulic Controller Removal And Installation...........................................338 Removal And Installation................................................................340 Hydrostatic Pump Startup................................................................342 Parts Identification....................................................................343 High Pressure Relief And Bypass Valve...................................................344 Charge Relief Valve.....................................................................345 Disassembly.............................................................................346 Inspection..............................................................................355 Assembly................................................................................359 Mechanical Neutral Adjustment...........................................................369 Hydraulic Controller Neutral Adjustment.................................................372 DRIVE BELT..................................................................................375 Belt Adjustment.........................................................................375 Belt Replacement........................................................................375 Stop Adjustment.........................................................................377 Tensioner Pulley Removal And Installation...............................................378 Tensioner Pulley Disassembly And Assembly...............................................378 DRAIN MANIFOLD..............................................................................381 Description.............................................................................381 Drain Manifold Removal And Installation.................................................381 DRIVE SYSTEM....................................................................................383 BRAKE.......................................................................................385 Description.............................................................................385 Block Removal And Installation..........................................................385 Block Disassembly And Assembly..........................................................387 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED)..............................................389 Description.............................................................................389 Checking Tension........................................................................390 Adjusting Tension.......................................................................391 Track Removal And Installation..........................................................392 Idler (Front) Removal And Installation..................................................394 Track Tensioner Disassembly And Assembly................................................397 Idler (Rear) Removal And Installation...................................................399 Roller Removal And Installation.........................................................399 Sprocket Removal And Installation (Single Speed)........................................400 Sprocket Removal And Installation (Two-Speed)...........................................400 Track Housing Removal And Installation..................................................401 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION)..........................................403 Description.............................................................................403 Checking Tension........................................................................404 Adjusting Tension.......................................................................405 Track Removal And Installation..........................................................406 Idler (Front) Removal And Installation..................................................408 Track Tensioner Disassembly And Assembly................................................411 Idler (Rear) Removal And Installation...................................................413 Roller Removal And Installation.........................................................413 Leaf Spring Removal And Installation....................................................414 Sprocket Removal And Installation.......................................................415 Track Housing Removal And Installation..................................................416 TRACK MAINTENANCE...........................................................................417 Track Damage Identification.............................................................417 MAINFRAME.......................................................................................429 SEAT BAR....................................................................................433 Description.............................................................................433 Removal And Installation................................................................433 Disassembly And Assembly................................................................434 Compression Spring Disassembly And Assembly.............................................435 OPERATOR CAB................................................................................437 Gas Spring Removal And Installation.....................................................437 Gas Spring Bracket Disassembly And Assembly.............................................438 Removal And Installation................................................................438 OPERATOR SEAT (SUSPENSION)..................................................................441 Removal And Installation................................................................441 Slide Rail Removal And Installation.....................................................441 Seat Belt Removal And Installation......................................................442 Lower Cushion Removal...................................................................442 Lower Cushion Installation..............................................................443 Back Cushion Removal And Installation...................................................443 Shock Removal And Installation..........................................................444 3-Point Seat Belt Removal And Installation..............................................444 BOB-TACH (HAND LEVER).......................................................................447 Description.............................................................................447 Removal And Installation................................................................447 Lever And Wedge Disassembly And Assembly................................................449 Pivot Pin Bushing And Seal Removal And Installation.....................................451 BOB-TACH (POWER)............................................................................453 Description.............................................................................453 Removal And Installation................................................................453 Lever And Wedge Disassembly And Assembly................................................456 Pivot Pin Bushing And Seal Removal And Installation.....................................457 LIFT ARMS...................................................................................459 Stabilizer Bar Removal And Installation.................................................459 Link Removal And Installation...........................................................460 Removal And Installation................................................................461 REAR GRILLE.................................................................................465 Removal And Installation................................................................465 REAR DOOR (TAILGATE)........................................................................467 Removal And Installation................................................................467 Striker Removal And Installation........................................................468 Striker Disassembly And Assembly........................................................468 Striker (Adjusting).....................................................................468 Latch Removal And Installation..........................................................469 FUEL TANK...................................................................................471 Removal And Installation................................................................471 Fuel Level Sender Removal And Installation..............................................473 Fuel Fill Screen Removal And Installation...............................................473 CONTROL PEDALS AND LINKAGES.................................................................475 Description.............................................................................475 Pedal Removal And Installation..........................................................475 Linkage Removal And Installation........................................................476 Pedal (Adjusting).......................................................................477 Floor Pan Removal And Installation......................................................478 CONTROL PEDALS AND LINKAGES (ACS)...........................................................479 Description.............................................................................479 Pedal Removal And Installation..........................................................479 Linkage Removal And Installation........................................................480 Pedal (Adjusting).......................................................................480 Floor Pan Removal And Installation......................................................481 CONTROL PANEL...............................................................................483 Description.............................................................................483 Removal And Installation................................................................484 Disassembly And Assembly................................................................485 Linkage Removal And Installation........................................................487 Pintle Arm Disassembly And Assembly.....................................................491 Linkage Neutral (Adjusting).............................................................492 Linkage Travel (Adjusting)..............................................................496 Shock Removal And Installation..........................................................500 CONTROL PANEL (SJC).........................................................................501 Description.............................................................................501 Removal And Installation................................................................501 CONTROL HANDLE / LEVER......................................................................503 Description.............................................................................503 Lever Removal And Installation..........................................................503 Boot Removal And Installation...........................................................504 CONTROL HANDLE / LEVER (ACS)................................................................505 Description.............................................................................505 Handle Sensor Removal And Installation..................................................505 Handle Removal And Installation.........................................................508 Handle Disassembly And Assembly.........................................................509 Lever Removal And Installation..........................................................509 Boot Removal And Installation...........................................................510 CONTROL HANDLE / LEVER (SJC)................................................................511 Description.............................................................................511 Joystick Testing........................................................................511 Joystick Removal And Installation.......................................................512 ACCESS PANEL (INSIDE).......................................................................513 Removal And Installation (Left).........................................................513 Removal And Installation (Right)........................................................513 ACCESS PANEL (INSIDE) (SJC).................................................................515 Removal And Installation (Left).........................................................515 Removal And Installation (Right)........................................................515 WINDOW (REAR)...............................................................................517 Removal And Installation................................................................517 Disassembly And Assembly................................................................517 WINDOW (TOP)................................................................................519 Removal And Installation................................................................519 WINDOW (SIDE)...............................................................................521 Removal And Installation................................................................521 CAB DOOR....................................................................................523 Description.............................................................................523 Removal And Installation................................................................523 Disassembly And Assembly................................................................524 Aligning................................................................................525 Adjusting...............................................................................526 Checking Operation......................................................................526 ARMREST.....................................................................................527 Description.............................................................................527 Removal And Installation................................................................528 Disassembly And Assembly................................................................529 LEFT SIDE LOWER PANEL.......................................................................531 Removal And Installation................................................................531 Disassembly And Assembly................................................................533 RIGHT SIDE LOWER PANEL......................................................................535 Removal And Installation................................................................535 Disassembly And Assembly................................................................536 HEADLINER...................................................................................539 Removal And Installation................................................................539 ELECTRICAL SYSTEM AND ANALYSIS..................................................................541 ELECTRICAL SCHEMATICS.......................................................................545 ELECTRICAL SYSTEM INFORMATION...............................................................635 Glossary Of Electrical Symbols..........................................................635 Standard Cab Harness Connectors.........................................................638 Deluxe Cab Harness Connectors...........................................................639 Mainframe Harness Connectors............................................................640 Description.............................................................................641 Troubleshooting.........................................................................642 Fuse And Relay Location / Identification................................................643 Solenoid Testing........................................................................645 BATTERY.....................................................................................647 Removal And Installation................................................................647 Servicing...............................................................................648 Using A Booster Battery (Jump Starting).................................................649 ALTERNATOR..................................................................................651 Belt Adjustment.........................................................................651 Belt Replacement........................................................................651 Charging System Inspection..............................................................652 Alternator Voltage Testing..............................................................653 Low Voltage Testing.....................................................................653 High Voltage Testing....................................................................654 Removal And Installation................................................................655 Parts Identification....................................................................656 STARTER.....................................................................................657 Testing.................................................................................657 Removal And Installation................................................................657 Parts Identification....................................................................658 INSTRUMENT PANELS...........................................................................659 Left Panel..............................................................................659 Display Screen..........................................................................661 Right Panel (Standard Key Panel)........................................................662 Right Panel (Keyless Start Panel).......................................................663 Right Panel (Deluxe Instrumentation Panel)..............................................664 Left Switch Panel.......................................................................666 Right Switch Panel......................................................................666 Left Panel Removal And Installation.....................................................667 Right Panel (Standard Key Panel) Removal And Installation...............................667 Right Panel (Keyless Start Panel) Removal And Installation..............................668 Right Panel (Deluxe Instrumentation Panel) Removal And Installation.....................668 Key Switch Disassembly And Assembly.....................................................669 Alarm Disassembly And Assembly..........................................................669 Left Switch Panel Removal And Installation..............................................670 Right Switch Panel Removal And Installation.............................................670 LIGHTS......................................................................................671 Front Removal And Installation..........................................................671 Rear Removal And Installation...........................................................672 Cab Light Removal And Installation......................................................672 BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)..................................................673 Description.............................................................................673 Connector Identification................................................................674 Removal And Installation................................................................680 BOBCAT CONTROLLER (ACS).....................................................................681 Description.............................................................................681 Connector And Wire Identification.......................................................682 Removal And Installation................................................................683 BOBCAT CONTROLLER (SJC) (DRIVE).............................................................685 Description.............................................................................685 Connector Identification................................................................686 Removal And Installation................................................................688 SPEED SENSORS (SJC).........................................................................689 Description.............................................................................689 Testing.................................................................................689 Removal And Installation................................................................690 DIAGNOSTIC SERVICE CODES....................................................................693 Viewing Service Codes...................................................................693 Service Codes List......................................................................694 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™).....................................................699 Description.............................................................................699 Inspecting The BICS™ (Engine STOPPED - Key ON)..........................................700 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....700 Inspecting The Seat Bar Sensor (Engine RUNNING).........................................700 Inspecting The Traction Lock (Engine RUNNING)...........................................700 Inspecting The Lift Arm Bypass Control..................................................700 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)........................700 Troubleshooting.........................................................................701 SEAT BAR SENSOR.............................................................................703 Description.............................................................................703 Troubleshooting.........................................................................703 Testing.................................................................................704 Removal And Installation................................................................705 Bobcat Interlock Control System (BICS™) Circuit Test....................................708 TRACTION LOCK...............................................................................711 Description.............................................................................711 Troubleshooting.........................................................................712 Inspecting..............................................................................713 CONTROL SYSTEM (ACS)........................................................................715 Description.............................................................................715 Troubleshooting.........................................................................716 Handle Sensor Connector Disassembly And Assembly........................................717 Switch Handle Removal...................................................................718 Switch Handle Installation..............................................................720 Actuator Connector Disassembly And Assembly.............................................723 Handle Lock Solenoid Removal And Installation...........................................724 Handle Lock Solenoid Disassembly And Assembly...........................................724 Foot Sensor Removal And Installation....................................................725 Foot Sensor Disassembly And Assembly....................................................726 Foot Sensor Lock Solenoid Removal And Installation......................................726 ELECTRICAL / HYDRAULIC CONTROLS.............................................................727 Identification Chart....................................................................727 Description.............................................................................728 Identification Chart ACD Group 0........................................................729 Identification Chart ACD Group 1........................................................730 Identification Chart ACD Group 2........................................................731 Identification Chart ACD Group 3........................................................732 ELECTRICAL / HYDRAULIC CONTROLS (ACS).......................................................733 Identification Chart....................................................................733 Description.............................................................................734 Identification Chart ACD Group 0........................................................735 Identification Chart ACD Group 1........................................................736 Identification Chart ACD Group 2........................................................737 Identification Chart ACD Group 3........................................................738 ELECTRICAL / HYDRAULIC CONTROLS (SJC).......................................................739 Identification Chart....................................................................739 Description.............................................................................740 Identification Chart ACD Group 0........................................................741 Identification Chart ACD Group 1........................................................742 Identification Chart ACD Group 2........................................................743 Identification Chart ACD Group 3........................................................744 SERVICE PC (LAPTOP COMPUTER)................................................................745 Connecting Remote Start Tool............................................................745 Connecting Remote Start Tool (Service Tool).............................................745 CALIBRATION.................................................................................747 Description.............................................................................747 Actuator Testing........................................................................747 Lift And Tilt Calibration (SJC).........................................................750 Hydrostatic Pump Calibration (SJC)......................................................752 Lift And Tilt Calibration (ACS).........................................................757 STEERING DRIFT COMPENSATION.................................................................759 Description.............................................................................759 Operation...............................................................................759 FLYWHEEL RPM SENSOR.........................................................................761 Description.............................................................................761 Adjustment..............................................................................762 CONTROL PANEL SETUP.........................................................................763 Right Panel Setup (Deluxe Instrumentation Panel)........................................763 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...............................................765 Password Description....................................................................765 Changing The Owner Password.............................................................765 Changing The User Passwords.............................................................766 Password Lockout Feature................................................................766 PASSWORD SETUP (KEYLESS START PANEL)........................................................767 Password Description....................................................................767 Changing The Owner Password.............................................................767 Password Lockout Feature................................................................767 MAINTENANCE CLOCK...........................................................................769 Description.............................................................................769 Setup...................................................................................770 Reset...................................................................................773 BACK-UP ALARM SYSTEM........................................................................775 Description.............................................................................775 Inspecting..............................................................................775 Adjusting Switch Position...............................................................776 Troubleshooting (Standard And ACS)......................................................777 Troubleshooting (Joystick)..............................................................778 Alarm Removal And Installation..........................................................779 Switch Removal And Installation.........................................................779 FRONT HORN..................................................................................781 Removal And Installation................................................................781 ENGINE SERVICE..................................................................................783 ENGINE INFORMATION..........................................................................787 Description.............................................................................787 Specifications..........................................................................788 Torque Values...........................................................................791 Troubleshooting.........................................................................791 Engine Removal And Installation.........................................................793 Engine Mount Replacement................................................................800 Compression - Checking..................................................................801 ENGINE SPEED CONTROL (SCPA).................................................................803 Removal And Installation................................................................803 Disassembly And Assembly................................................................803 Cable Removal And Installation..........................................................804 ENGINE SPEED CONTROL (SJC)..................................................................805 Removal And Installation................................................................805 Disassembly And Assembly................................................................806 MUFFLER.....................................................................................809 Removal And Installation................................................................809 AIR CLEANER.................................................................................811 Housing Removal And Installation........................................................811 ENGINE COOLING SYSTEM.......................................................................813 Radiator Removal And Installation.......................................................813 Hydraulic Fan Description...............................................................816 Hydraulic Fan Disassembly And Assembly..................................................817 Lower Fan Duct Removal And Installation.................................................818 Blower Housing Removal And Installation.................................................818 Hydraulic Fan Motor Assembly Removal And Installation...................................819 Fan Removal And Installation............................................................819 Hydraulic Fan Motor Removal And Installation............................................820 Water Pump Removal And Installation.....................................................821 Water Pump Disassembly And Assembly.....................................................821 Thermostat Housing Removal And Installation.............................................822 Thermostat - Checking...................................................................822 LUBRICATION SYSTEM..........................................................................823 Oil Pan Removal And Installation........................................................823 Oil Pump Removal And Installation.......................................................824 Oil Pump Inspection.....................................................................824 Oil Filter Cooler Removal And Installation..............................................826 Engine Oil Pressure - Testing...........................................................827 FUEL SYSTEM.................................................................................829 Fuel Shutoff Solenoid - Checking........................................................829 Fuel Shutoff Solenoid Removal And Installation..........................................829 Fuel Injection Pump Assembly Removal....................................................830 Fuel Injection Pump Assembly Installation...............................................833 Governor Housing Disassembly And Assembly...............................................836 Governor Disassembly And Assembly.......................................................837 Fuel Camshaft Removal And Installation..................................................839 Fuel Injection Pump Removal.............................................................841 Injection Pump - Timing.................................................................847 Fuel Injector Removal And Installation..................................................850 Fuel Injector Nozzle Pressure - Checking................................................851 Nozzle Spraying Condition...............................................................852 Valve Seat Tightness....................................................................852 CYLINDER HEAD...............................................................................853 Intake Air Heater - Testing.............................................................853 Intake Air Heater Removal And Installation..............................................853 Valve Clearance Adjustment..............................................................854 Valve Timing - Checking.................................................................856 Cylinder Head Removal And Installation..................................................857 Cylinder Head Disassembly And Assembly..................................................859 Cylinder Head - Servicing...............................................................860 Cylinder Head Top Clearance.............................................................861 Valve Guide - Checking..................................................................862 Reconditioning The Valve And Valve Seat.................................................864 Valve Spring............................................................................866 Valve Tappets...........................................................................867 Rocker Arm And Shaft - Checking.........................................................868 Push Rod Alignment - Checking...........................................................868 CRANKSHAFT AND PISTONS......................................................................869 Piston And Connecting Rod Removal And Installation......................................869 Piston And Connecting Rod - Servicing...................................................871 Cylinder Bore - Checking................................................................875 Connecting Rod Alignment................................................................876 Crankshaft Gear Removal And Installation................................................876 Crankshaft And Bearings Removal.........................................................877 Crankshaft And Bearings Installation....................................................879 Crankshaft And Bearings - Servicing.....................................................881 CAMSHAFT AND TIMING GEARS...................................................................887 Timing Gearcase Cover Removal And Installation..........................................887 Timing Gears Backlash - Checking........................................................888 Idler Gear And Camshaft Removal And Installation........................................888 Camshaft - Servicing....................................................................889 Idler Gear And Shaft - Servicing........................................................891 TURBOCHARGER................................................................................893 Description.............................................................................893 Testing.................................................................................893 Removal And Installation................................................................895 FLYWHEEL AND HOUSING........................................................................897 Flywheel Removal And Installation.......................................................897 Ring Gear Removal And Installation......................................................897 Housing Removal And Installation........................................................898 HEATING, VENTILATION, AIR CONDITIONING..........................................................899 AIR CONDITIONING SYSTEM FLOW................................................................901 Description.............................................................................901 Chart...................................................................................902 Components..............................................................................903 Safety Equipment........................................................................906 REGULAR MAINTENANCE.........................................................................907 Filters.................................................................................907 Compressor Drive Belt Adjustment........................................................908 Compressor Drive Belt Replacement.......................................................908 Condenser...............................................................................908 Air Conditioning Lubrication............................................................908 Air Conditioning Service Chart..........................................................909 Evaporator / Heater Coil................................................................910 TROUBLESHOOTING.............................................................................911 Blower Motor Does Not Operate...........................................................911 Blower Motor Operates Normally, But Air Flow Is Insufficient............................911 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............911 The Compressor Does Not Operate At All, Or Operates Improperly..........................911 Gauge Pressure Related Troubleshooting..................................................912 Troubleshooting Tree....................................................................914 Temperature / Pressure Chart............................................................918 Poor A/C Performance....................................................................920 HVAC Repair And Leaks...................................................................921 Electrical System.......................................................................922 Engine Coolant Bypassing The Heater Valve...............................................928 Heater Valve Not Opening Or Closing.....................................................929 SYSTEM CHARGING AND RECLAMATION.............................................................931 Refrigerant Identification..............................................................931 Reclamation And Charging With Recovery / Charging Unit..................................932 COMPRESSOR..................................................................................935 Removal And Installation................................................................935 Oil.....................................................................................936 Oil Check...............................................................................937 CONDENSER...................................................................................939 Removal And Installation................................................................939 RECEIVER / DRIER............................................................................941 Receiver / Drier Removal And Installation...............................................941 Pressure Relief Valve Removal And Installation..........................................942 Pressure Switch Removal And Installation................................................943 Schrader® Valve Removal And Installation................................................944 EVAPORATOR / HEATER UNIT....................................................................945 Removal And Installation................................................................945 THERMOSTAT..................................................................................947 Description.............................................................................947 Removal And Installation................................................................948 EXPANSION VALVE.............................................................................949 Removal And Installation................................................................949 EVAPORATOR COIL.............................................................................951 Removal And Installation................................................................951 HEATER COIL.................................................................................953 Removal And Installation................................................................953 BLOWER FAN..................................................................................955 Removal And Installation................................................................955 Disassembly And Assembly................................................................955 HEATER VALVE................................................................................959 Removal And Installation................................................................959 SPECIFICATIONS..................................................................................961 (T770) LOADER SPECIFICATIONS................................................................963 Machine Dimensions......................................................................963 Performance.............................................................................964 Engine..................................................................................965 Drive System............................................................................965 Controls................................................................................966 Hydraulic System........................................................................966 Electrical System.......................................................................967 Capacities..............................................................................967 Tracks..................................................................................968 Ground Pressure.........................................................................968 TORQUE SPECIFICATIONS FOR BOLTS.............................................................969 Torque For General SAE Bolts............................................................969 Torque For General Metric Bolts.........................................................970 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................971 Straight Thread O-ring Fitting..........................................................971 Flare Fitting...........................................................................972 Tubelines And Hoses.....................................................................972 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................973 Specifications..........................................................................973 CONVERSIONS.................................................................................975 Decimal And Millimeter Equivalent Chart.................................................975 U.S. To Metric Conversion Chart.........................................................975 ALPHABETICAL INDEX..............................................................................977
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S.V
