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Bobcat T770 Skid-Steer Loader Service Manual 7252384 – PDF DOWNLOAD
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Bobcat T770 Skid-Steer Loader Service Manual 7252384 – PDF DOWNLOAD
S/N AT6311001 & Above
S/N B3BW11001 & Above
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Description
Bobcat T770 Skid-Steer Loader Service Manual 7252384 – PDF DOWNLOAD
FILE DETAILS:
Bobcat T770 Skid-Steer Loader Service Manual 7252384 – PDF DOWNLOAD
Language : English
Pages : 1230
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T770 Skid-Steer Loader Service Manual 7252384 – PDF DOWNLOAD
S/N AT6311001 & Above
S/N B3BW11001 & Above
FOREWORD:
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
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® attachment mounting system 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 all machine fluid levels.
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 Skid-Steer Loader Service Manual 7252384 – 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...................................................................................... 26 Removing........................................................................................ 27 OPERATOR CAB........................................................................................ 29 Description..................................................................................... 29 Raising......................................................................................... 30 Lowering........................................................................................ 31 Cab Door Sensor................................................................................. 32 Special Applications Kit........................................................................ 33 Special Applications Kit Inspection And Maintenance............................................. 33 Forestry Door And Window Kit.................................................................... 34 Forestry Door And Window Kit Inspection And Maintenance......................................... 34 TRANSPORTING THE LOADER ON A TRAILER................................................................ 35 Loading And Unloading........................................................................... 35 Fastening....................................................................................... 35 TOWING THE LOADER................................................................................... 37 Procedure....................................................................................... 37 REMOTE START TOOL KIT - MEL1563..................................................................... 39 Remote Start Tool - MEL1563..................................................................... 39 Service Tool Harness Communicator - MEL1566..................................................... 41 Remote Start Procedure.......................................................................... 41 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666...................................................... 45 Description..................................................................................... 45 Remote Start Tool (Service Tool) - 7022042...................................................... 46 Loader Service Tool Harness - 6689747........................................................... 47 Computer Service Tool Harness - 6689746......................................................... 48 Remote Start Procedure.......................................................................... 49 SERVICE SCHEDULE.................................................................................... 53 Maintenance Intervals........................................................................... 53 ENGINE AIR CLEANER.................................................................................. 55 Replacing Filters............................................................................... 55 ENGINE COOLING SYSTEM............................................................................... 57 Maintenance Platform............................................................................ 57 Cleaning........................................................................................ 57 Checking And Adding Coolant..................................................................... 60 Removing And Replacing Coolant.................................................................. 61 FUEL SYSTEM......................................................................................... 63 Fuel Specifications............................................................................. 63 Biodiesel Blend Fuel............................................................................ 63 Filling The Fuel Tank........................................................................... 64 Fuel Filter..................................................................................... 65 Removing Air From The Fuel System............................................................... 66 DIESEL EXHAUST FLUID (DEF) / ADBLUE® SYSTEM......................................................... 67 Description..................................................................................... 67 Filling The DEF / AdBlue® Tank.................................................................. 67 ENGINE LUBRICATION SYSTEM........................................................................... 69 Checking And Adding Engine Oil.................................................................. 69 Engine Oil Chart................................................................................ 69 Removing And Replacing Oil And Filter........................................................... 70 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................................................................ 78 BOB-TACH (HAND LEVER)............................................................................... 79 Inspection And Maintenance...................................................................... 79 BOB-TACH (POWER).................................................................................... 81 Inspection And Maintenance...................................................................... 81 LUBRICATING THE LOADER.............................................................................. 83 Lubrication Locations........................................................................... 83 Track Roller And Idler Lubrication.............................................................. 86 PIVOT PINS.......................................................................................... 87 Inspection And Maintenance...................................................................... 87 LOADER STORAGE AND RETURN TO SERVICE................................................................ 89 Storage......................................................................................... 89 Return To Service............................................................................... 89 STOPPING THE ENGINE AND LEAVING THE LOADER.......................................................... 91 Procedure....................................................................................... 91 EMERGENCY EXIT...................................................................................... 93 Rear Window Identification...................................................................... 93 Rear Window Removal (Latches)................................................................... 93 Rear Window Removal (Rubber Cord)............................................................... 93 External Access (Rear Window With Latches)...................................................... 94 External Access (Rear Window With Rubber Cord).................................................. 94 Front Door...................................................................................... 94 SEAT BELT........................................................................................... 97 Inspection And Maintenance...................................................................... 97 HYDRAULIC SYSTEM........................................................................................ 99 HYDRAULIC / HYDROSTATIC SCHEMATICS.................................................................. 105 HYDRAULIC SYSTEM INFORMATION........................................................................ 117 Glossary Of Hydraulic / Hydrostatic Symbols..................................................... 117 Troubleshooting................................................................................. 121 CYLINDER (LIFT)..................................................................................... 123 Testing......................................................................................... 123 Removal And Installation........................................................................ 124 Parts Identification............................................................................ 128 Disassembly..................................................................................... 129 Assembly........................................................................................ 130 CYLINDER (TILT)..................................................................................... 135 Testing......................................................................................... 135 Removal And Installation........................................................................ 136 Base End Pivot Pin Removal And Installation..................................................... 138 Parts Identification............................................................................ 139 Disassembly..................................................................................... 140 Assembly........................................................................................ 142 CYLINDER (BOB-TACH)................................................................................. 145 Testing......................................................................................... 145 Removal And Installation........................................................................ 146 Parts Identification............................................................................ 147 Disassembly..................................................................................... 148 Assembly........................................................................................ 149 MAIN RELIEF VALVE................................................................................... 153 Description..................................................................................... 153 Testing......................................................................................... 154 Main Relief Valve Adjustment.................................................................... 156 Main Relief Valve Removal And Installation...................................................... 156 Auxiliary Relief Valve Adjustment............................................................... 157 Auxiliary Relief Valve Removal And Installation................................................. 158 HYDRAULIC CONTROL VALVE (STANDARD).................................................................. 159 Description..................................................................................... 159 Removal And Installation........................................................................ 160 Mount Bracket Removal And Installation.......................................................... 164 Identification Chart............................................................................ 165 Lift Load Check Valve Removal And Installation.................................................. 166 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 167 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 168 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 168 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 169 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 169 Port Relief Valve Removal And Installation...................................................... 170 Plug Removal And Installation................................................................... 172 Rubber Boot Removal And Installation............................................................ 173 End Cap Block Removal And Installation.......................................................... 173 Lift Spool And Detent Removal................................................................... 174 Lift Spool And Detent Disassembly............................................................... 176 Lift Spool And Detent Assembly.................................................................. 178 Lift Spool And Detent Installation.............................................................. 180 Tilt Spool Removal And Installation............................................................. 182 Tilt Spool Disassembly And Assembly............................................................. 183 Auxiliary Spool Removal And Installation........................................................ 184 Auxiliary Solenoid Removal And Installation..................................................... 185 Solenoid Removal And Installation............................................................... 186 Lock Valve Removal And Installation............................................................. 187 Lift Arm Bypass Orifice Removal And Installation................................................ 189 Main Relief Valve Removal And Installation...................................................... 189 Auxiliary Relief Valve Removal And Installation................................................. 190 Check Valve Removal And Installation............................................................ 190 HYDRAULIC CONTROL VALVE (ACS) OR (SJC).............................................................. 193 Description..................................................................................... 193 Removal And Installation........................................................................ 193 Actuator Removal And Installation (In Loader)................................................... 198 Actuator Removal And Installation (Out Of Loader)............................................... 199 Identification Chart............................................................................ 202 Mount Bracket Removal And Installation.......................................................... 203 Lift Load Check Valve Removal And Installation.................................................. 203 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 204 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 205 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 205 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 206 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 206 Port Relief Valve Removal And Installation...................................................... 207 Plug Removal And Installation................................................................... 209 End Cap Block Removal And Installation.......................................................... 210 Lift Spool Removal And Installation............................................................. 210 Lift Spool Disassembly And Assembly............................................................. 212 Tilt Spool Removal And Installation............................................................. 213 Auxiliary Spool Removal And Installation........................................................ 215 Auxiliary Solenoid Removal And Installation..................................................... 216 Solenoid Removal And Installation............................................................... 217 Lock Valve Removal And Installation............................................................. 218 Lift Arm Bypass Orifice Removal And Installation................................................ 220 Main Relief Valve Removal And Installation...................................................... 220 Auxiliary Relief Valve Removal And Installation................................................. 221 Check Valve Removal And Installation............................................................ 221 LIFT ARM BYPASS CONTROL VALVE....................................................................... 223 Description..................................................................................... 223 Testing......................................................................................... 223 Removal And Installation........................................................................ 224 Bracket Removal And Installation................................................................ 225 Disassembly And Assembly........................................................................ 225 HYDRAULIC PUMP...................................................................................... 227 Description..................................................................................... 227 Pump Test At Quick Couplers..................................................................... 227 Direct Pump Test (Standard Section)............................................................. 228 Direct Pump Test (Charge Section)............................................................... 230 Removal And Installation........................................................................ 232 Hydraulic Pump Startup.......................................................................... 234 Parts Identification............................................................................ 235 Disassembly And Assembly........................................................................ 236 HYDRAULIC PUMP (HIGH FLOW).......................................................................... 237 Description..................................................................................... 237 Pump Test At Quick Couplers..................................................................... 237 Direct Pump Test (Standard Section)............................................................. 238 Direct Pump Test (Charge Section)............................................................... 239 Direct Pump Test (High Flow Section)............................................................ 241 High Flow Relief Valve Adjustment............................................................... 243 High Flow Relief Valve Removal And Installation................................................. 244 Solenoid Removal And Installation............................................................... 245 Removal And Installation........................................................................ 246 Hydraulic Pump Startup.......................................................................... 248 Parts Identification............................................................................ 249 Disassembly And Assembly........................................................................ 250 HYDRAULIC / HYDROSTATIC FILTERS..................................................................... 251 Description..................................................................................... 251 Housing Removal And Installation................................................................ 251 HYDRAULIC FLUID RESERVOIR........................................................................... 253 Description..................................................................................... 253 Removal And Installation........................................................................ 253 Hydraulic Fluid Screen.......................................................................... 254 OIL COOLER.......................................................................................... 255 Description..................................................................................... 255 Removal And Installation........................................................................ 255 BUCKET POSITION VALVE............................................................................... 257 Description..................................................................................... 257 Solenoid Removal And Installation............................................................... 257 Solenoid Testing................................................................................ 259 Removal And Installation........................................................................ 259 Disassembly And Assembly........................................................................ 261 REAR AUXILIARY DIVERTER VALVE....................................................................... 263 Description..................................................................................... 263 Solenoid Testing................................................................................ 263 Removal And Installation........................................................................ 264 Disassembly And Assembly........................................................................ 265 BOB-TACH (POWER) BLOCK.............................................................................. 271 Description..................................................................................... 271 Testing Relief Valve............................................................................ 272 Removal And Installation........................................................................ 274 Disassembly And Assembly........................................................................ 276 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK............................................................. 281 Description..................................................................................... 281 Removal And Installation........................................................................ 282 Disassembly And Assembly (FFI/FI)............................................................... 282 Disassembly And Assembly (FFH/FH)............................................................... 284 AUTOMATIC RIDE CONTROL.............................................................................. 287 Description..................................................................................... 287 Removal And Installation........................................................................ 288 Checking The Pressure In The Accumulator........................................................ 291 Adding Nitrogen To The Accumulator.............................................................. 293 HYDROSTATIC SYSTEM...................................................................................... 295 HYDROSTATIC SYSTEM INFORMATION...................................................................... 297 Description..................................................................................... 297 Troubleshooting................................................................................. 298 HYDROSTATIC DRIVE MOTOR............................................................................. 299 Description..................................................................................... 299 Removing And Replacing Fluid.................................................................... 299 Removal And Installation........................................................................ 300 Parts Identification............................................................................ 302 Disassembly And Assembly........................................................................ 304 HYDROSTATIC DRIVE MOTOR (TWO-SPEED)................................................................. 317 Description..................................................................................... 317 Removing And Replacing Fluid.................................................................... 317 Removal And Installation........................................................................ 318 Parts Identification............................................................................ 320 Disassembly And Assembly........................................................................ 322 HYDROSTATIC DRIVE MOTOR (LATER MODELS WITH EIGHT TRACK SPROCKET BOLTS).............................. 335 Description..................................................................................... 335 Removing And Replacing Fluid.................................................................... 335 Removal And Installation........................................................................ 336 Parts Identification (Single Speed)............................................................. 338 Parts Identification (Two-Speed)................................................................ 340 Disassembly And Assembly........................................................................ 342 CHARGE PRESSURE..................................................................................... 357 Description..................................................................................... 357 Testing......................................................................................... 358 Sender Removal And Installation................................................................. 359 Adjusting....................................................................................... 360 HYDROSTATIC PUMP.................................................................................... 363 Description..................................................................................... 363 Removal And Installation........................................................................ 364 Hydrostatic Pump Startup........................................................................ 365 Replenishing / High Pressure Relief Valve Removal And Installation.............................. 365 Parts Identification (Left Half)................................................................ 366 Parts Identification (Right Half)............................................................... 367 Disassembly..................................................................................... 368 Assembly........................................................................................ 375 HYDROSTATIC PUMP (SJC).............................................................................. 383 Description..................................................................................... 383 Hydraulic Controller Removal And Installation................................................... 384 Removal And Installation........................................................................ 386 Hydrostatic Pump Startup........................................................................ 388 Parts Identification............................................................................ 389 High Pressure Relief And Bypass Valve........................................................... 390 Charge Relief Valve............................................................................. 391 Disassembly..................................................................................... 392 Inspection...................................................................................... 401 Assembly........................................................................................ 405 Mechanical Neutral Adjustment................................................................... 414 Hydraulic Controller Neutral Adjustment......................................................... 417 DRIVE BELT.......................................................................................... 421 Belt Adjustment................................................................................. 421 Stop Adjustment................................................................................. 421 Belt Replacement................................................................................ 422 Tensioner Pulley Removal And Installation (Earlier Models)...................................... 424 Tensioner Pulley Disassembly And Assembly....................................................... 424 Tensioner Pulley Removal And Installation (Later Models)........................................ 425 Tensioner Pulley Disassembly And Assembly....................................................... 425 TWO-SPEED / BRAKE VALVE............................................................................. 427 Description..................................................................................... 427 Valve Block Removal And Installation............................................................ 428 Valve Block Disassembly And Assembly............................................................ 430 DRAIN MANIFOLD...................................................................................... 433 Description..................................................................................... 433 Removal And Installation........................................................................ 433 DRIVE SYSTEM............................................................................................ 435 BRAKE............................................................................................... 437 Description..................................................................................... 437 Block Removal And Installation.................................................................. 437 Block Disassembly And Assembly.................................................................. 438 BRAKE (TWO-SPEED)................................................................................... 441 Description..................................................................................... 441 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) (S/N B3BW11001 - B3BW11999).......................... 443 Description..................................................................................... 443 Checking Tension................................................................................ 444 Adjusting Tension............................................................................... 445 Track Removal And Installation.................................................................. 446 Idler (Front) Removal And Installation.......................................................... 448 Track Tensioner Disassembly And Assembly........................................................ 451 Idler (Rear) Removal And Installation........................................................... 453 Roller Removal And Installation................................................................. 453 Sprocket Removal And Installation (Single Speed)................................................ 454 Sprocket Removal And Installation (Two-Speed)................................................... 454 Track Housing Removal And Installation.......................................................... 455 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) (S/N B3BW11001 - B3BW11999)...................... 457 Description..................................................................................... 457 Checking Tension................................................................................ 458 Adjusting Tension............................................................................... 459 Track Removal And Installation.................................................................. 460 Idler (Front) Removal And Installation.......................................................... 462 Track Tensioner Disassembly And Assembly........................................................ 465 Idler (Rear) Removal And Installation........................................................... 467 Roller Removal And Installation................................................................. 467 Leaf Spring Removal And Installation............................................................ 468 Sprocket Removal And Installation (Single Speed)................................................ 469 Sprocket Removal And Installation (Two-Speed)................................................... 469 Track Housing Removal And Installation.......................................................... 470 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) (S/N AT6311001 AND B3BW12001 & ABOVE)................ 471 Description..................................................................................... 471 Checking (Solid-Mounted Undercarriage).......................................................... 473 Adjusting (Solid-Mounted Undercarriage) (Earlier Models With Two Track Tension Fittings)........ 474 Adjusting (Solid-Mounted Undercarriage) (Later Models With One Track Tension Fitting)........... 475 Track Removal And Installation.................................................................. 476 Idler (Front) Removal And Installation.......................................................... 479 Track Tensioner Removal And Installation........................................................ 480 Track Tensioner Disassembly And Assembly........................................................ 481 Idler (Rear) Removal And Installation........................................................... 483 Roller Removal And Installation................................................................. 483 Sprocket Removal And Installation (Single Speed)................................................ 484 Sprocket Removal And Installation (Two-Speed)................................................... 484 Sprocket Removal And Installation (Later Models With Eight Track Sprocket Bolts)................ 484 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) (S/N AT6311001 AND B3BW12001 & ABOVE)............ 485 Description..................................................................................... 485 Checking (Roller Suspension Undercarriage)...................................................... 487 Adjusting (Roller Suspension Undercarriage) (Earlier Models With Two Track Tension Fittings).... 488 Adjusting (Roller Suspension Undercarriage) (Later Models With One Track Tension Fitting)....... 489 Track Removal And Installation.................................................................. 490 Idler (Front) Removal And Installation.......................................................... 493 Track Tensioner Removal And Installation........................................................ 494 Track Tensioner Disassembly And Assembly........................................................ 495 Idler (Rear) Removal And Installation........................................................... 497 Roller Removal And Installation................................................................. 497 Leaf Spring Removal And Installation............................................................ 498 Sprocket Removal And Installation (Single Speed)................................................ 499 Sprocket Removal And Installation (Two-Speed)................................................... 499 Sprocket Removal And Installation (Later Models With Eight Track Sprocket Bolts)................ 499 TRACK MAINTENANCE................................................................................... 501 Track Damage Identification..................................................................... 501 MAINFRAME............................................................................................... 513 SEAT BAR............................................................................................ 517 Description..................................................................................... 517 Removal And Installation........................................................................ 517 Disassembly And Assembly........................................................................ 518 Compression Spring Disassembly And Assembly..................................................... 519 OPERATOR CAB........................................................................................ 521 Gas Spring Removal And Installation............................................................. 521 Gas Spring Bracket Disassembly And Assembly..................................................... 522 Removal And Installation........................................................................ 522 OPERATOR SEAT....................................................................................... 525 Removal And Installation........................................................................ 525 Seat Belt Removal And Installation (Retractable)................................................ 525 Seat Belt And Bracket Removal And Installation (Standard)....................................... 526 Seat Belt Bracket Removal And Installation...................................................... 526 OPERATOR SEAT (SUSPENSION).......................................................................... 527 Removal And Installation........................................................................ 527 Slide Rail Removal And Installation............................................................. 527 Seat Belt Removal And Installation.............................................................. 528 Lower Cushion Removal........................................................................... 528 Lower Cushion Installation...................................................................... 529 Back Cushion Removal And Installation........................................................... 529 Shock Removal And Installation.................................................................. 530 3-Point Seat Belt Removal And Installation...................................................... 530 BOB-TACH (HAND LEVER)............................................................................... 533 Description..................................................................................... 533 Removal And Installation........................................................................ 533 Lever And Wedge Disassembly And Assembly........................................................ 535 Pivot Pin Bushing And Seal Removal And Installation............................................. 538 BOB-TACH (POWER).................................................................................... 539 Description..................................................................................... 539 Removal And Installation........................................................................ 539 Lever And Wedge Disassembly And Assembly........................................................ 542 Pivot Pin Bushing And Seal Removal And Installation............................................. 544 LIFT ARMS........................................................................................... 545 Stabilizer Bar Removal And Installation......................................................... 545 Link Removal And Installation................................................................... 546 Removal And Installation........................................................................ 547 REAR GRILLE......................................................................................... 551 Removing........................................................................................ 551 Installing...................................................................................... 551 Shield Removal And Installation................................................................. 552 ENGINE COVER........................................................................................ 553 Removal And Installation........................................................................ 553 REAR DOOR (TAILGATE)................................................................................ 555 Removal And Installation........................................................................ 555 Striker Removal And Installation................................................................ 556 Striker Disassembly And Assembly................................................................ 556 Striker (Adjusting)............................................................................. 556 Latch Removal And Installation.................................................................. 557 Tailgate Fan Removal And Installation........................................................... 558 FUEL TANK........................................................................................... 559 Removal And Installation........................................................................ 559 Fuel Level Sender Removal And Installation...................................................... 560 Fuel Fill Screen Removal And Installation....................................................... 561 CONTROL PEDALS AND LINKAGES......................................................................... 563 Description..................................................................................... 563 Pedal Removal And Installation.................................................................. 563 Linkage Removal And Installation................................................................ 564 Pedal (Adjusting)............................................................................... 565 Floor Pan Removal And Installation.............................................................. 566 CONTROL PEDALS AND LINKAGES (ACS)................................................................... 567 Description..................................................................................... 567 Pedal Removal And Installation.................................................................. 567 Linkage Removal And Installation................................................................ 568 Pedal (Adjusting)............................................................................... 568 Floor Pan Removal And Installation.............................................................. 569 CONTROL PANEL....................................................................................... 571 Description..................................................................................... 571 Removal And Installation........................................................................ 572 Disassembly And Assembly........................................................................ 574 Linkage Removal And Installation................................................................ 576 Pintle Arm Disassembly And Assembly............................................................. 579 Linkage Neutral (Adjusting)..................................................................... 580 Linkage Travel (Adjusting)...................................................................... 584 Shock Removal And Installation.................................................................. 588 CONTROL PANEL (SJC)................................................................................. 589 Description..................................................................................... 589 Removal And Installation........................................................................ 589 CONTROL HANDLE / LEVER.............................................................................. 591 Description..................................................................................... 591 Lever Removal And Installation.................................................................. 591 Boot Removal And Installation................................................................... 592 CONTROL HANDLE / LEVER (ACS)........................................................................ 593 Description..................................................................................... 593 Handle Sensor Removal And Installation.......................................................... 593 Handle Removal And Installation................................................................. 596 Handle Disassembly And Assembly................................................................. 597 Lever Removal And Installation.................................................................. 597 Boot Removal And Installation................................................................... 598 CONTROL HANDLE / LEVER (SJC)........................................................................ 599 Description..................................................................................... 599 Joystick Testing................................................................................ 599 Joystick Removal And Installation............................................................... 600 ACCESS PANEL (INSIDE)............................................................................... 601 Removal And Installation (Left)................................................................. 601 Removal And Installation (Right)................................................................ 601 ACCESS PANEL (INSIDE) (SJC)......................................................................... 603 Removal And Installation (Left)................................................................. 603 Removal And Installation (Right)................................................................ 603 WINDOW (REAR)....................................................................................... 605 Rear Window Identification...................................................................... 605 Rear Window Removal (Latches)................................................................... 605 Rear Window Removal (Rubber Cord)............................................................... 605 External Access (Rear Window With Latches)...................................................... 606 External Access (Rear Window With Rubber Cord).................................................. 606 WINDOW (TOP)........................................................................................ 607 Removal And Installation........................................................................ 607 WINDOW (SIDE)....................................................................................... 609 Removal And Installation........................................................................ 609 CAB DOOR............................................................................................ 611 Description..................................................................................... 611 Removal And Installation........................................................................ 611 Disassembly And Assembly........................................................................ 612 Aligning........................................................................................ 613 Adjusting....................................................................................... 614 Checking Operation.............................................................................. 614 ARMREST............................................................................................. 615 Description..................................................................................... 615 Removal And Installation........................................................................ 616 Disassembly And Assembly........................................................................ 617 LEFT SIDE LOWER PANEL............................................................................... 619 Removal And Installation........................................................................ 619 Disassembly And Assembly........................................................................ 621 RIGHT SIDE LOWER PANEL.............................................................................. 623 Removal And Installation........................................................................ 623 Disassembly And Assembly........................................................................ 624 HEADLINER........................................................................................... 627 Removal And Installation........................................................................ 627 FAN DUCT PANELS..................................................................................... 629 Removal And Installation........................................................................ 629 ELECTRICAL SYSTEM....................................................................................... 631 ELECTRICAL SCHEMATICS............................................................................... 637 ELECTRICAL SYSTEM INFORMATION....................................................................... 791 Glossary Of Electrical Symbols.................................................................. 791 Standard Cab Harness Connectors................................................................. 794 Deluxe Cab Harness Connectors................................................................... 795 Mainframe Manual Harness Connectors............................................................. 796 Mainframe SJC, AHC, ACS Harness Connectors...................................................... 797 Engine Harness Connectors....................................................................... 798 Description..................................................................................... 799 Troubleshooting................................................................................. 800 Fuse And Relay Location / Identification........................................................ 801 Solenoid Testing................................................................................ 807 BATTERY............................................................................................. 809 Removal And Installation........................................................................ 809 Battery Maintenance............................................................................. 810 Maintaining Battery Charge Level................................................................ 810 Battery Service During Machine Storage.......................................................... 810 Battery Testing................................................................................. 811 Battery Charging................................................................................ 811 Using A Booster Battery (Jump Starting)......................................................... 812 ALTERNATOR.......................................................................................... 813 Belt Adjustment................................................................................. 813 Belt Replacement................................................................................ 813 Charging System Inspection...................................................................... 814 Alternator Voltage Testing...................................................................... 815 Low Voltage Testing............................................................................. 815 High Voltage Testing............................................................................ 816 Removal And Installation........................................................................ 817 Parts Identification............................................................................ 819 STARTER............................................................................................. 821 Testing......................................................................................... 821 Removal And Installation........................................................................ 821 Parts Identification............................................................................ 822 INSTRUMENT PANELS................................................................................... 823 Left Panel...................................................................................... 823 Display Screen.................................................................................. 825 Right Panel (Standard Key Panel)................................................................ 826 Right Panel (Keyless Start Panel)............................................................... 827 Right Panel (Deluxe Instrumentation Panel)...................................................... 828 Left Switch Panel............................................................................... 830 Right Switch Panel.............................................................................. 830 Left Side Lower Panel........................................................................... 831 Right Side Lower Panel.......................................................................... 831 Left Panel Removal And Installation............................................................. 832 Right Panel (Standard Key Panel) Removal And Installation....................................... 832 Right Panel (Keyless Start Panel) Removal And Installation...................................... 833 Right Panel (Deluxe Instrumentation Panel) Removal And Installation............................. 833 Key Switch Disassembly And Assembly............................................................. 834 Alarm Disassembly And Assembly.................................................................. 834 Left Switch Panel Removal And Installation...................................................... 835 Right Switch Panel Removal And Installation..................................................... 835 LIGHTS.............................................................................................. 837 Front Removal And Installation.................................................................. 837 Rear Removal And Installation................................................................... 838 Cab Light Removal And Installation.............................................................. 838 BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY).......................................................... 839 Description..................................................................................... 839 Connector Identification........................................................................ 840 Removal And Installation........................................................................ 846 BOBCAT CONTROLLER (ACS)............................................................................. 847 Description..................................................................................... 847 Connector And Wire Identification............................................................... 848 Removal And Installation........................................................................ 849 BOBCAT CONTROLLER (SJC) (DRIVE)..................................................................... 851 Description..................................................................................... 851 Connector Identification........................................................................ 852 Removal And Installation........................................................................ 854 DOSING CONTROL UNIT (DCU)........................................................................... 855 Description..................................................................................... 855 Removal And Installation........................................................................ 855 ENGINE CONTROL UNIT (ECU)........................................................................... 857 Description..................................................................................... 857 Cleaning........................................................................................ 858 Removal And Installation........................................................................ 859 DIAGNOSTIC SERVICE CODES............................................................................ 861 Viewing Service Codes........................................................................... 861 Service Codes List.............................................................................. 862 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)............................................................. 877 Description..................................................................................... 877 Operation....................................................................................... 877 Inspecting The BICS™ (Engine STOPPED - Key ON).................................................. 878 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)............ 878 Inspecting The Seat Bar Sensor (Engine RUNNING)................................................. 878 Inspecting The Traction Lock And Parking Brake (Engine RUNNING)................................. 878 Inspecting The Lift Arm Bypass Control.......................................................... 878 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)................................ 878 Troubleshooting................................................................................. 879 SEAT BAR SENSOR..................................................................................... 881 Description..................................................................................... 881 Troubleshooting................................................................................. 881 Testing......................................................................................... 882 Removal......................................................................................... 883 Installation.................................................................................... 884 Bobcat Interlock Control System (BICS™) Circuit Test............................................ 886 TRACTION LOCK....................................................................................... 889 Description..................................................................................... 889 Troubleshooting................................................................................. 890 Inspecting...................................................................................... 891 CONTROL SYSTEM (ACS)................................................................................ 893 Description..................................................................................... 893 Troubleshooting................................................................................. 894 Handle Sensor Connector Disassembly And Assembly................................................ 895 Switch Handle Removal........................................................................... 896 Switch Handle Installation...................................................................... 898 Actuator Connector Disassembly And Assembly..................................................... 901 Handle Lock Solenoid Removal And Installation................................................... 902 Handle Lock Solenoid Disassembly And Assembly................................................... 902 Foot Sensor Removal And Installation............................................................ 903 Foot Sensor Disassembly And Assembly............................................................ 904 Foot Sensor Lock Solenoid Removal And Installation.............................................. 904 ELECTRICAL / HYDRAULIC CONTROLS..................................................................... 905 Identification Chart............................................................................ 905 Description..................................................................................... 906 Identification Chart ACD Group 0................................................................ 907 Identification Chart ACD Group 1................................................................ 908 Identification Chart ACD Group 2................................................................ 909 Identification Chart ACD Group 3................................................................ 910 ELECTRICAL / HYDRAULIC CONTROLS (ACS)............................................................... 911 Identification Chart............................................................................ 911 Description..................................................................................... 912 Identification Chart ACD Group 0................................................................ 913 Identification Chart ACD Group 1................................................................ 914 Identification Chart ACD Group 2................................................................ 915 Identification Chart ACD Group 3................................................................ 916 ELECTRICAL / HYDRAULIC CONTROLS (SJC)............................................................... 917 Identification Chart............................................................................ 917 Description..................................................................................... 918 Identification Chart ACD Group 0................................................................ 919 Identification Chart ACD Group 1................................................................ 920 Identification Chart ACD Group 2................................................................ 921 Identification Chart ACD Group 3................................................................ 922 SERVICE PC (LAPTOP COMPUTER)........................................................................ 923 Connecting Remote Start Tool.................................................................... 923 Connecting Remote Start Tool (Service Tool)..................................................... 923 CALIBRATION......................................................................................... 925 Description..................................................................................... 925 Actuator Testing................................................................................ 925 Lift And Tilt Calibration (SJC)................................................................. 928 Hydrostatic Pump Calibration (SJC).............................................................. 930 Lift And Tilt Calibration (ACS)................................................................. 935 STEERING DRIFT COMPENSATION (OPERATOR MODE)......................................................... 937 Description..................................................................................... 937 Operation....................................................................................... 937 STEERING DRIFT COMPENSATION (SERVICE MODE).......................................................... 939 Description..................................................................................... 939 Operation....................................................................................... 939 CONTROL PANEL SETUP................................................................................. 941 Right Panel Setup (Deluxe Instrumentation Panel)................................................ 941 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....................................................... 945 Password Description............................................................................ 945 Changing The Owner Password..................................................................... 945 Changing The User Passwords..................................................................... 946 Password Lockout Feature........................................................................ 946 PASSWORD SETUP (KEYLESS START PANEL)................................................................ 947 Password Description............................................................................ 947 Changing The Owner Password..................................................................... 947 Password Lockout Feature........................................................................ 947 MAINTENANCE CLOCK................................................................................... 949 Description..................................................................................... 949 Setup........................................................................................... 950 Reset........................................................................................... 953 BACK-UP ALARM SYSTEM................................................................................ 955 Description..................................................................................... 955 Inspection...................................................................................... 955 Adjusting Switch Position....................................................................... 956 Troubleshooting (Standard And ACS).............................................................. 957 Troubleshooting (Joystick)...................................................................... 958 Alarm Removal And Installation.................................................................. 959 Switch Removal And Installation................................................................. 959 FRONT HORN.......................................................................................... 961 Removal And Installation........................................................................ 961 Troubleshooting................................................................................. 962 Troubleshooting (Joystick)...................................................................... 963 CAMSHAFT AND CRANKSHAFT POSITION SENSOR............................................................. 965 Removal And Installation........................................................................ 965 ENGINE COMPARTMENT TEMPERATURE SENSOR............................................................... 967 Removal And Installation........................................................................ 967 TELEMATICS.......................................................................................... 969 Description..................................................................................... 969 Removal And Installation........................................................................ 969 Procedure....................................................................................... 970 ENGINE SERVICE.......................................................................................... 971 ENGINE INFORMATION.................................................................................. 975 Description..................................................................................... 975 Specifications.................................................................................. 976 Sensor Location................................................................................. 978 Torque Values................................................................................... 985 Troubleshooting................................................................................. 987 Engine Removal And Installation................................................................. 989 Engine Mount Replacement........................................................................1000 Compression - Testing...........................................................................1002 Injector Signal - Testing.......................................................................1004 Injector Signal - Testing (In-Line).............................................................1006 Oil Pressure Testing (At Oil Sensor On Block)...................................................1008 Oil Pressure Testing (At Turbocharger Oil Inlet)................................................1010 ENGINE SPEED CONTROL (HAND).........................................................................1013 Removal And Installation........................................................................1013 ENGINE SPEED CONTROL (FOOT).........................................................................1015 Removal And Installation........................................................................1015 Disassembly And Assembly........................................................................1016 Foot Throttle Calibration.......................................................................1018 SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM..........................................................1021 Description.....................................................................................1021 Diesel Exhaust Fluid (DEF) / AdBlue® Level......................................................1022 DeSOX Process...................................................................................1023 SCR System Codes................................................................................1025 Diesel Exhaust Fluid (DEF) / AdBlue® Unsatisfactory Quality.....................................1026 SCR System Component Tampering..................................................................1026 EGR Impeded.....................................................................................1027 Diesel Exhaust Fluid (DEF) / AdBlue® Dosing Interruption........................................1027 SCR Removal And Installation....................................................................1028 Dosing Module Removal And Installation..........................................................1030 Dosing Control Unit (DCU) Removal And Installation..............................................1031 Supply Module Removal And Installation..........................................................1033 Supply Module Filter Removal And Installation...................................................1034 Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal And Installation..............................1036 Diesel Exhaust Fluid (DEF) / AdBlue® Sensor Removal And Installation............................1039 Diesel Exhaust Fluid (DEF) / AdBlue® Coolant Valve Removal And Installation.....................1041 DIESEL OXIDATION CATALYST (DOC).....................................................................1043 Removal And Installation........................................................................1043 AIR CLEANER.........................................................................................1045 Housing Removal And Installation................................................................1045 ENGINE COOLING SYSTEM...............................................................................1047 Radiator Removal And Installation...............................................................1047 Hydraulic Fan Description.......................................................................1050 Reversible Hydraulic Fan Description............................................................1050 Fan Duct Removal And Installation...............................................................1050 Hydraulic Fan Motor Assembly Removal And Installation...........................................1051 Hydraulic Fan Motor Removal And Installation....................................................1052 Hydraulic Fan Motor Disassembly And Assembly....................................................1054 Blower Housing Removal And Installation.........................................................1063 Water Pump Removal And Installation.............................................................1063 Thermostat Housing Removal And Installation.....................................................1064 Thermostat - Testing............................................................................1064 LUBRICATION SYSTEM..................................................................................1065 Description.....................................................................................1065 Oil Pan Removal And Installation................................................................1066 Oil Pump Removal And Installation...............................................................1067 Oil Pump Relief Valve Description...............................................................1068 Oil Suction Tube Removal And Installation.......................................................1068 Oil Cooler Removal And Installation.............................................................1069 Oil Filter Head Removal And Installation........................................................1069 Oil Cooler Bypass Description...................................................................1070 FUEL SYSTEM.........................................................................................1071 Description.....................................................................................1071 High Pressure Pump Removal And Installation.....................................................1072 High Pressure Pump Drive Gear Removal And Installation..........................................1073 Fuel Cooler Removal And Installation............................................................1074 Fuel Bypass Valve Removal And Installation......................................................1074 Fuel Temperature Sensor Removal And Installation................................................1074 Fuel Recirculation Valve Removal And Installation...............................................1075 Fuel Rail Assembly Removal And Installation.....................................................1076 Fuel Injector Removal And Installation..........................................................1077 Injector Coding.................................................................................1079 Removing Air From The Fuel System...............................................................1081 CYLINDER HEAD.......................................................................................1083 Intake Air Heater Removal And Installation......................................................1083 Intake Air Heater Tube Removal And Installation.................................................1084 Valve Clearance Adjustment......................................................................1085 Cylinder Head Removal And Installation..........................................................1087 Cylinder Head Disassembly And Assembly..........................................................1090 Cylinder Head Inspection........................................................................1091 Cylinder Head Top Clearance.....................................................................1092 Valve Step Height...............................................................................1093 Valve Stem Height...............................................................................1093 Valve Guide.....................................................................................1094 Valve...........................................................................................1094 Valve Spring....................................................................................1095 Rocker Arm Shaft Disassembly And Assembly.......................................................1096 Rocker Arm Shaft Inspection.....................................................................1097 Push Rod Inspection.............................................................................1097 CRANKSHAFT AND PISTONS..............................................................................1099 Piston And Connecting Rod Removal And Installation..............................................1099 Piston And Connecting Rod Inspection............................................................1100 Timing Wheel Removal And Installation...........................................................1102 Crankshaft Removal And Installation.............................................................1104 Cylinder Block Inspection.......................................................................1106 Crankshaft Inspection...........................................................................1108 Connecting Rod Inspection.......................................................................1108 Engine Component Class..........................................................................1109 CAMSHAFT............................................................................................1111 Removal And Installation........................................................................1111 Inspecting......................................................................................1112 GEARCASE............................................................................................1115 Gear Backlash...................................................................................1115 Gear End Play...................................................................................1115 Gear Timing.....................................................................................1116 Idle Gear Removal And Installation..............................................................1117 Idle Gear Inspection............................................................................1117 TURBOCHARGER........................................................................................1119 Description.....................................................................................1119 Removal And Installation........................................................................1119 Inspection......................................................................................1121 FLYWHEEL AND HOUSING................................................................................1123 Flywheel Removal And Installation...............................................................1123 Ring Gear Removal And Installation..............................................................1123 Housing Removal And Installation................................................................1124 EXHAUST GAS RECIRCULATION (EGR) SYSTEM..............................................................1125 Description.....................................................................................1125 Removal And Installation........................................................................1126 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................1129 AIR CONDITIONING SYSTEM FLOW........................................................................1131 Description.....................................................................................1131 Chart...........................................................................................1132 Components......................................................................................1133 Safety Equipment................................................................................1136 REGULAR MAINTENANCE.................................................................................1137 Filters.........................................................................................1137 Belt Adjustment.................................................................................1138 Belt Replacement................................................................................1138 Condenser.......................................................................................1139 Air Conditioning Lubrication....................................................................1139 Air Conditioning Service Chart..................................................................1140 Air Conditioning Evaporator / Heater Coil.......................................................1141 TROUBLESHOOTING.....................................................................................1143 Blower Motor Does Not Operate...................................................................1143 Blower Motor Operates Normally, But Air Flow Is Insufficient....................................1143 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal......................1143 The Compressor Does Not Operate At All, Or Operates Improperly..................................1143 Gauge Pressure Related Troubleshooting..........................................................1144 Troubleshooting Tree............................................................................1146 Temperature / Pressure Chart....................................................................1149 Poor A/C Performance............................................................................1151 HVAC Repair And Leaks...........................................................................1152 Electrical System...............................................................................1153 Engine Coolant Bypassing The Heater Valve.......................................................1159 Heater Valve Not Opening Or Closing.............................................................1160 SYSTEM CHARGING AND RECLAMATION.....................................................................1161 Refrigerant Identification......................................................................1161 Reclamation And Charging With Recovery / Charging Unit..........................................1162 COMPRESSOR..........................................................................................1165 Removal And Installation........................................................................1165 Oil.............................................................................................1167 Oil Check.......................................................................................1168 CONDENSER...........................................................................................1169 Removal And Installation........................................................................1169 RECEIVER / DRIER....................................................................................1171 Receiver / Drier Removal And Installation.......................................................1171 Pressure Switch Removal And Installation........................................................1173 Schrader® Valve Removal And Installation........................................................1174 EVAPORATOR / HEATER UNIT............................................................................1175 Removal And Installation........................................................................1175 THERMOSTAT..........................................................................................1177 Description.....................................................................................1177 Removal And Installation........................................................................1178 EXPANSION VALVE.....................................................................................1179 Removal And Installation........................................................................1179 EVAPORATOR COIL.....................................................................................1181 Removal And Installation........................................................................1181 HEATER COIL.........................................................................................1183 Removal And Installation........................................................................1183 BLOWER FAN..........................................................................................1185 Removal And Installation........................................................................1185 Disassembly And Assembly........................................................................1185 HEATER VALVE........................................................................................1189 Removal And Installation........................................................................1189 EVAPORATOR / HEATER COVER...........................................................................1191 Removing........................................................................................1191 Installing......................................................................................1191 SPECIFICATIONS..........................................................................................1193 LOADER SPECIFICATIONS...............................................................................1195 Machine Dimensions..............................................................................1195 Performance.....................................................................................1196 Engine..........................................................................................1196 Drive System....................................................................................1197 Controls........................................................................................1197 Hydraulic System................................................................................1198 Electrical System...............................................................................1199 Capacities......................................................................................1199 Tracks..........................................................................................1200 Ground Pressure.................................................................................1200 TECHINCAL SERVICE GUIDE SPECIFICATIONS..............................................................1201 Engine..........................................................................................1201 Engine Torques..................................................................................1201 Cooling System..................................................................................1201 Loader Torques..................................................................................1202 Hydraulic / Hydrostatic System..................................................................1202 Fuel Consumption................................................................................1202 TORQUE SPECIFICATIONS FOR BOLTS.....................................................................1203 Torque For General SAE Bolts....................................................................1203 Torque For General Metric Bolts.................................................................1204 HYDRAULIC CONNECTION SPECIFICATIONS.................................................................1205 Straight Thread O-ring Fitting..................................................................1205 Flare Fitting...................................................................................1206 Tubelines And Hoses.............................................................................1206 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS........................................................1207 Specifications..................................................................................1207 CONVERSIONS.........................................................................................1209 Decimal And Millimeter Equivalent Chart.........................................................1209 U.S. To Metric Conversion Chart.................................................................1209 SERVICE TOOLS REQUIRED..............................................................................1211 Remote Start Tools..............................................................................1211 Hydraulic Tools.................................................................................1212 Mainframe And Drive Tools.......................................................................1215 Electrical Tools................................................................................1218 Engine Tools....................................................................................1219 HVAC Tools......................................................................................1224 ALPHABETICAL INDEX......................................................................................1225
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