Bobcat All-Wheel Steer Loaders A770 Repair Service Manuals + Operation & Maintenance Manuals
Complete repair service manual with electrical wiring diagrams for Bobcat A770 All-Wheel Steer Loaders, with all the technical information to maintain, diagnose, repair, and service like professional mechanics.
Bobcat All-Wheel Steer Loaders A770 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
6989479 (3-11) - A770 All-Wheel Steer Loader Operation & Maintenance Manual.pdf
6989479 (12-10) - A770 All-Wheel Steer Loader Operation & Maintenance Manual.pdf
6989480 (1-11) - A770 All-Wheel Steer Loader Service Manual.pdf
6989480 (11-12) - A770 All-Wheel Steer Loader Service Manual.pdf
6990114 (3-11) - A770 All-Wheel Steer Loader Operation & Maintenance Manual.pdf
6990115 (09-11) - A770 All-Wheel Steer Loader Service Manual.pdf
6990245 (06-12) - A770 All-Wheel Steer Loader Service Manual.pdf
PRODUCT DETAILS:
Total Pages: 4,332 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
TABLE CONTENTS
FOREWORD. . . II
SAFETY INSTRUCTIONS . .. . V
FIRE PREVENTION . . VII
SERIAL NUMBER LOCATION . .. IX
DELIVERY REPORT. X
BOBCAT LOADER IDENTIFICATION. . .XI
SAFETY & MAINTENANCE . .10-01
HYDRAULIC SYSTEM . .. . 20-01
HYDROSTATIC SYSTEM . .. . 30-01
DRIVE SYSTEM . 40-01
MAINFRAME. . 50-01
ELECTRICAL SYSTEM ANALYSIS . . . 60-01
ENGINE SERVICE . .. 70-01
HEATING, VENTILATION, AIR CONDITIONING . .. 80-01
SPECIFICATIONS. .. . . SPEC-01
…
CONTENTS
FOREWORD. . . . II
SAFETY INSTRUCTIONS . . . . V
FIRE PREVENTION . VII
SERIAL NUMBER LOCATIONS . . IX
DELIVERY REPORT. . X
LOADER IDENTIFICATION . . .XI
SAFETY AND MAINTENANCE. . 10-01
HYDRAULIC SYSTEM . . . . 20-01
HYDROSTATIC SYSTEM . . . . 30-01
DRIVE SYSTEM . . 40-01
MAINFRAME. . . 50-01
ELECTRICAL SYSTEM & ANALYSIS. . . . 60-01
ENGINE SERVICE . . . . . 70-01
HEATING, VENTILATION, AIR CONDITIONING . . . . 80-01
SPECIFICATIONS. . . . . SPEC-01
6989479 (12-10) - A770 All-Wheel Steer Loader Operation & Maintenance Manual....2
OPERATOR SAFETY WARNINGS....4
CONTENTS....6
FOREWORD....8
BOBCAT COMPANY IS IS0 9001 CERTIFIED....10
REGULAR MAINTENANCE ITEMS....10
SERIAL NUMBER LOCATIONS....11
Loader Serial Number....11
Engine Serial Number....11
DELIVERY REPORT....11
LOADER IDENTIFICATION....12
FEATURES, ACCESSORIES AND ATTACHMENTS....13
Standard Items....13
Options And Accessories....13
Buckets Available....14
Attachments....14
High-Flow Attachments....14
Special Applications Kit....15
Special Applications Kit Inspection And Maintenance....15
Forestry Door And Window Kit....16
Forestry Door And Window Kit Inspection And Maintenance....16
SAFETY & TRAINING RESOURCES....18
SAFETY INSTRUCTIONS....20
Before Operation....20
Safe Operation Is The Operator?s Responsibility....21
Safe Operation Needs A Qualified Operator....21
Avoid Silica Dust....22
FIRE PREVENTION....22
Maintenance....22
Operation....22
Electrical....22
Hydraulic System....23
Fueling....23
Starting....23
Spark Arrestor Exhaust System....23
Welding And Grinding....23
Fire Extinguishers....23
PUBLICATIONS AND TRAINING RESOURCES....24
MACHINE SIGNS (DECALS)....25
No-Text Safety Signs....28
OPERATING INSTRUCTIONS....30
INSTRUMENT PANEL IDENTIFICATION....34
Overview....34
Left Panel....35
Display Screen....37
Right Panel (Standard Key Panel)....37
Right Panel (Keyless Start Panel)....38
Right Panel (Deluxe Instrumentation Panel)....39
Left Switch Panel....41
Right Switch Panel....41
Left Side Lower Panel....42
Right Side Lower Panel....42
Radio....43
CONTROL IDENTIFICATION....45
Standard Controls....45
OPERATOR CAB....46
Description....46
Cab Light....46
Door Operation....46
Front Wiper....47
Side Windows....47
SEAT BAR RESTRAINT SYSTEM....48
Operation....48
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....49
Operation....49
LIFT ARM BYPASS CONTROL....50
Operation....50
PARKING BRAKE....50
Operation....50
STEERING MODE SELECTION....51
Operation....51
TRACTION LOCK OVERRIDE....51
Operation....51
ENGINE SPEED CONTROL....52
Operation....52
EMERGENCY EXIT....53
External Access....53
Rear Window....53
Front Door....53
BACK-UP ALARM SYSTEM....55
Description....55
Operation....55
DRIVING AND STEERING THE LOADER....56
All-Wheel Steer Mode....56
Stopping The Loader (All-Wheel Steer Mode)....56
Skid-Steer Mode....57
Stopping The Loader (Skid-Steer Mode)....57
TWO-SPEED CONTROL....58
Description....58
Operation....58
SPEED MANAGEMENT....59
Operation....59
Changing The Factory Default Setting....60
DRIVE RESPONSE....61
Description....61
Operation....61
STEERING DRIFT COMPENSATION....63
Description....63
Operation....63
HYDRAULIC CONTROLS....65
Description....65
Lift Arm Operation....65
Lift Arm Float Position....65
Tilt Operation....65
Hydraulic Bucket Positioning....66
FRONT Auxiliary Hydraulics Operation....66
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....67
FRONT Auxiliary Hydraulics Operation (REVERSE CONTINUOUS FLOW)....67
REAR Auxiliary Hydraulics Operation....68
High-Flow Hydraulics Operation....69
Quick Couplers....69
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....70
ATTACHMENT CONTROL DEVICE (ACD)....71
Description....71
DAILY INSPECTION....72
Daily Inspection And Maintenance....72
PRE-STARTING PROCEDURE....74
Entering The Loader....74
Operation & Maintenance Manual And Operator?s Handbook Locations....74
Seat Adjustment....75
Joystick Position Adjustment....76
Seat Belt Adjustment....76
Seat Bar....76
STARTING THE ENGINE....77
Standard Key Panel....77
Keyless Start Panel....79
Deluxe Instrumentation Panel....81
Cold Temperature Starting....83
Warming The Hydraulic / Hydrostatic System....83
MONITORING THE DISPLAY PANELS....84
Left Panel....84
Warning And Shutdown....84
STOPPING THE ENGINE AND LEAVING THE LOADER....85
Procedure....85
COUNTERWEIGHTS....86
Description....86
Effect On The Loader And Loader Operation....86
When To Consider Using Counterweights....86
When To Consider Removing Counterweights....86
Accessories That Affect Machine Weight....86
ATTACHMENTS....87
Choosing The Correct Bucket....87
Pallet Fork....87
Installing And Removing The Attachment (Hand Lever Bob-Tach)....88
Installing And Removing The Attachment (Power Bob-Tach)....90
OPERATING PROCEDURE....94
Inspect The Work Area....94
Basic Operating Instructions....94
Driving On Public Roads....94
Operating With A Full Bucket....95
Operating With An Empty Bucket....95
Filling And Emptying The Bucket....96
Leveling The Ground Using Float....97
Digging And Filling A Hole....98
TOWING THE LOADER....99
Procedure....99
LIFTING THE LOADER....99
Single-Point Lift....99
Four-Point Lift....100
TRANSPORTING THE LOADER ON A TRAILER....101
Loading And Unloading....101
Fastening....101
PREVENTIVE MAINTENANCE....102
MAINTENANCE SAFETY....106
SERVICE SCHEDULE....108
Chart....108
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....109
Inspecting The BICS (Engine STOPPED - Key ON)....109
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....109
Inspecting The Seat Bar Sensor (Engine RUNNING)....109
Inspecting The Traction Lock (Engine RUNNING)....109
Inspecting The Lift Arm Bypass Control....109
Inspecting Deactivation Of Lift And Tilt Functions....109
SEAT BAR RESTRAINT SYSTEM....110
Description....110
Inspecting....110
Maintaining....110
SEAT BELT....111
Inspection And Maintenance....111
LIFT ARM SUPPORT DEVICE....112
Installing....112
Removing....113
BACK-UP ALARM SYSTEM....114
Description....114
Inspecting....114
OPERATOR CAB....115
Description....115
Raising....115
Lowering....116
Cab Door Sensor....117
REAR DOOR (TAILGATE)....118
Opening And Closing....118
Adjusting....118
REAR GRILLE....119
Removing....119
Installing....119
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....120
Cleaning And Maintenance....120
Filters....120
Evaporator / Heater Coil....120
Condenser....121
Air Conditioning Lubrication....121
Troubleshooting....121
AIR CLEANER SERVICE....121
Replacing Filter Elements....121
FUEL SYSTEM....123
Fuel Specifications....123
Biodiesel Blend Fuel....123
Filling The Fuel Tank....124
Fuel Filter....125
Removing Air From The Fuel System....125
ENGINE LUBRICATION SYSTEM....126
Checking And Adding Engine Oil....126
Engine Oil Chart....126
Removing And Replacing Oil And Filter....127
ENGINE COOLING SYSTEM....128
Maintenance Platform....128
Cleaning....128
Checking Level....130
Removing And Replacing Coolant....130
ELECTRICAL SYSTEM....131
Description....131
Fuse And Relay Location / Identification....131
Battery Maintenance....133
Using A Booster Battery (Jump Starting)....134
Removing And Installing Battery....135
HYDRAULIC / HYDROSTATIC SYSTEM....136
Checking And Adding Fluid....136
Hydraulic / Hydrostatic Fluid Chart....136
Removing And Replacing Hydraulic Fluid....137
Removing And Replacing Hydraulic / Hydrostatic Filter....139
Removing And Replacing Steering Filter....140
Removing And Replacing Hydraulic Charge Filter....141
Breather Cap....142
SPARK ARRESTER MUFFLER....143
Cleaning Procedure....143
TIRE MAINTENANCE....144
Wheel Nuts....144
Rotating....144
Mounting....144
FINAL DRIVE TRANSMISSION (CHAINCASE)....145
Checking And Adding Oil....145
Removing And Replacing Oil....145
ALTERNATOR BELT....146
Belt Adjustment....146
Belt Replacement....146
AIR CONDITIONING BELT....147
Belt Adjustment....147
Belt Replacement....147
DRIVE BELT....148
Belt Adjustment....148
Stop Adjustment....148
Belt Replacement....148
WHEEL ALIGNMENT....150
Wheel Position Sensors....150
Aligning The Wheels....150
LUBRICATING THE LOADER....151
Lubrication Locations....151
PIVOT PINS....154
Inspection And Maintenance....154
BOB-TACH (HAND LEVER)....155
Inspection And Maintenance....155
BOB-TACH (POWER)....156
Inspection And Maintenance....156
LOADER STORAGE AND RETURN TO SERVICE....157
Storage....157
Return To Service....157
SYSTEM SETUP & ANALYSIS....158
DIAGNOSTIC SERVICE CODES....160
Viewing Service Codes....160
Service Codes List....161
CONTROL PANEL SETUP....166
Right Panel Setup (Deluxe Instrumentation Panel)....166
PASSWORD SETUP (KEYLESS START PANEL)....168
Password Description....168
Changing The Owner Password....168
Password Lockout Feature....168
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....169
Password Description....169
Changing The Owner Password....169
Changing The User Passwords....170
Password Lockout Feature....170
MAINTENANCE CLOCK....171
Description....171
Setup....171
Reset....171
MACHINE SIGN TRANSLATIONS....172
MACHINE SIGN TRANSLATIONS....174
Service Schedule (7167998)....174
Warning (7167993)....177
Warning (7169291)....177
Danger (7167989)....177
Danger (7167990)....177
Danger (7167988)....178
Warning (7167994)....179
Warning (7167996)....180
Warning (7168142)....180
Warning (7184346)....181
Danger (7170355)....181
Lift Arm Support Device (7169340)....182
Warning (7168148)....183
Warning (7142141)....184
Warning (7168019)....185
Warning (6737189)....186
SPECIFICATIONS....188
(A770) LOADER SPECIFICATIONS....190
Machine Dimensions....190
Performance....191
Engine....191
Drive System....192
Controls....192
Hydraulic System....193
Electrical System....194
Capacities....194
Tires....194
WARRANTY....196
WARRANTY....198
ALPHABETICAL INDEX....200
6989479 (3-11) - A770 All-Wheel Steer Loader Operation & Maintenance Manual....202
OPERATOR SAFETY WARNINGS....204
CONTENTS....206
FOREWORD....208
BOBCAT COMPANY IS IS0 9001 CERTIFIED....210
REGULAR MAINTENANCE ITEMS....210
SERIAL NUMBER LOCATIONS....211
Loader Serial Number....211
Engine Serial Number....211
DELIVERY REPORT....211
LOADER IDENTIFICATION....212
FEATURES, ACCESSORIES AND ATTACHMENTS....213
Standard Items....213
Options And Accessories....213
Buckets Available....214
Attachments....214
High-Flow Attachments....214
Special Applications Kit....215
Special Applications Kit Inspection And Maintenance....215
Forestry Door And Window Kit....216
Forestry Door And Window Kit Inspection And Maintenance....216
SAFETY & TRAINING RESOURCES....218
SAFETY INSTRUCTIONS....220
Before Operation....220
Safe Operation Is The Operator?s Responsibility....221
Safe Operation Needs A Qualified Operator....221
Avoid Silica Dust....222
FIRE PREVENTION....222
Maintenance....222
Operation....222
Electrical....222
Hydraulic System....223
Fueling....223
Starting....223
Spark Arrestor Exhaust System....223
Welding And Grinding....223
Fire Extinguishers....223
PUBLICATIONS AND TRAINING RESOURCES....224
MACHINE SIGNS (DECALS)....225
No-Text Safety Signs....228
OPERATING INSTRUCTIONS....230
INSTRUMENT PANEL IDENTIFICATION....234
Overview....234
Left Panel....235
Display Screen....237
Right Panel (Standard Key Panel)....237
Right Panel (Keyless Start Panel)....238
Right Panel (Deluxe Instrumentation Panel)....239
Left Switch Panel....241
Right Switch Panel....241
Left Side Lower Panel....242
Right Side Lower Panel....242
Radio....243
CONTROL IDENTIFICATION....245
Standard Controls....245
OPERATOR CAB....246
Description....246
Cab Light....246
Door Operation....246
Front Wiper....247
Side Windows....247
SEAT BAR RESTRAINT SYSTEM....248
Operation....248
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....249
Operation....249
LIFT ARM BYPASS CONTROL....250
Operation....250
PARKING BRAKE....250
Operation....250
STEERING MODE SELECTION....251
Operation....251
TRACTION LOCK OVERRIDE....251
Operation....251
ENGINE SPEED CONTROL....252
Operation....252
EMERGENCY EXIT....253
External Access....253
Rear Window....253
Front Door....253
BACK-UP ALARM SYSTEM....255
Description....255
Operation....255
DRIVING AND STEERING THE LOADER....256
All-Wheel Steer Mode....256
Stopping The Loader (All-Wheel Steer Mode)....256
Skid-Steer Mode....257
Stopping The Loader (Skid-Steer Mode)....257
TWO-SPEED CONTROL....258
Description....258
Operation....258
SPEED MANAGEMENT....259
Operation....259
Changing The Factory Default Setting....260
DRIVE RESPONSE....261
Description....261
Operation....261
STEERING DRIFT COMPENSATION....263
Description....263
Operation....263
HYDRAULIC CONTROLS....265
Description....265
Lift Arm Operation....265
Lift Arm Float Position....265
Tilt Operation....265
Hydraulic Bucket Positioning....266
FRONT Auxiliary Hydraulics Operation....266
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....267
FRONT Auxiliary Hydraulics Operation (REVERSE CONTINUOUS FLOW)....267
REAR Auxiliary Hydraulics Operation....268
High-Flow Hydraulics Operation....269
Quick Couplers....269
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....270
ATTACHMENT CONTROL DEVICE (ACD)....271
Description....271
DAILY INSPECTION....272
Daily Inspection And Maintenance....272
PRE-STARTING PROCEDURE....274
Entering The Loader....274
Operation & Maintenance Manual And Operator?s Handbook Locations....274
Seat Adjustment....275
Joystick Position Adjustment....276
Seat Belt Adjustment....276
Seat Bar....276
STARTING THE ENGINE....277
Standard Key Panel....277
Keyless Start Panel....279
Deluxe Instrumentation Panel....281
Cold Temperature Starting....283
Warming The Hydraulic / Hydrostatic System....283
MONITORING THE DISPLAY PANELS....284
Left Panel....284
Warning And Shutdown....284
STOPPING THE ENGINE AND LEAVING THE LOADER....285
Procedure....285
COUNTERWEIGHTS....286
Description....286
Effect On The Loader And Loader Operation....286
When To Consider Using Counterweights....286
When To Consider Removing Counterweights....286
Accessories That Affect Machine Weight....286
ATTACHMENTS....287
Choosing The Correct Bucket....287
Pallet Fork....287
Installing And Removing The Attachment (Hand Lever Bob-Tach)....288
Installing And Removing The Attachment (Power Bob-Tach)....290
OPERATING PROCEDURE....294
Inspect The Work Area....294
Basic Operating Instructions....294
Driving On Public Roads....294
Operating With A Full Bucket....295
Operating With An Empty Bucket....295
Filling And Emptying The Bucket....296
Leveling The Ground Using Float....297
Digging And Filling A Hole....298
TOWING THE LOADER....299
Procedure....299
LIFTING THE LOADER....299
Single-Point Lift....299
Four-Point Lift....300
TRANSPORTING THE LOADER ON A TRAILER....301
Loading And Unloading....301
Fastening....301
PREVENTIVE MAINTENANCE....302
MAINTENANCE SAFETY....306
SERVICE SCHEDULE....308
Chart....308
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....309
Inspecting The BICS? (Engine STOPPED - Key ON)....309
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....309
Inspecting The Seat Bar Sensor (Engine RUNNING)....309
Inspecting The Traction Lock (Engine RUNNING)....309
Inspecting The Lift Arm Bypass Control....309
Inspecting Deactivation Of Lift And Tilt Functions....309
SEAT BAR RESTRAINT SYSTEM....310
Description....310
Inspecting....310
Maintaining....310
SEAT BELT....311
Inspection And Maintenance....311
LIFT ARM SUPPORT DEVICE....312
Installing....312
Removing....313
BACK-UP ALARM SYSTEM....314
Description....314
Inspecting....314
OPERATOR CAB....315
Description....315
Raising....315
Lowering....316
Cab Door Sensor....317
REAR DOOR (TAILGATE)....318
Opening And Closing....318
Adjusting....318
REAR GRILLE....319
Removing....319
Installing....319
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....320
Cleaning And Maintenance....320
Filters....320
Evaporator / Heater Coil....320
Condenser....321
Air Conditioning Lubrication....321
Troubleshooting....321
AIR CLEANER SERVICE....321
Replacing Filter Elements....321
FUEL SYSTEM....323
Fuel Specifications....323
Biodiesel Blend Fuel....323
Filling The Fuel Tank....324
Fuel Filter....325
Removing Air From The Fuel System....325
ENGINE LUBRICATION SYSTEM....326
Checking And Adding Engine Oil....326
Engine Oil Chart....326
Removing And Replacing Oil And Filter....327
ENGINE COOLING SYSTEM....328
Maintenance Platform....328
Cleaning....328
Checking Level....330
Removing And Replacing Coolant....330
ELECTRICAL SYSTEM....331
Description....331
Fuse And Relay Location / Identification....331
Battery Maintenance....333
Using A Booster Battery (Jump Starting)....334
Removing And Installing Battery....335
HYDRAULIC / HYDROSTATIC SYSTEM....336
Checking And Adding Fluid....336
Hydraulic / Hydrostatic Fluid Chart....336
Removing And Replacing Hydraulic Fluid....337
Removing And Replacing Hydraulic / Hydrostatic Filter....339
Removing And Replacing Steering Filter....340
Removing And Replacing Hydraulic Charge Filter....341
Breather Cap....342
SPARK ARRESTER MUFFLER....343
Cleaning Procedure....343
TIRE MAINTENANCE....344
Wheel Nuts....344
Rotating....344
Mounting....344
FINAL DRIVE TRANSMISSION (CHAINCASE)....345
Checking And Adding Oil....345
Removing And Replacing Oil....345
ALTERNATOR BELT....346
Belt Adjustment....346
Belt Replacement....346
AIR CONDITIONING BELT....347
Belt Adjustment....347
Belt Replacement....347
DRIVE BELT....348
Belt Adjustment....348
Stop Adjustment....348
Belt Replacement....348
WHEEL ALIGNMENT....350
Wheel Position Sensors....350
Aligning The Wheels....350
LUBRICATING THE LOADER....351
Lubrication Locations....351
PIVOT PINS....354
Inspection And Maintenance....354
BOB-TACH (HAND LEVER)....355
Inspection And Maintenance....355
BOB-TACH (POWER)....356
Inspection And Maintenance....356
LOADER STORAGE AND RETURN TO SERVICE....357
Storage....357
Return To Service....357
SYSTEM SETUP & ANALYSIS....358
DIAGNOSTIC SERVICE CODES....360
Viewing Service Codes....360
Service Codes List....361
CONTROL PANEL SETUP....366
Right Panel Setup (Deluxe Instrumentation Panel)....366
PASSWORD SETUP (KEYLESS START PANEL)....368
Password Description....368
Changing The Owner Password....368
Password Lockout Feature....368
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....369
Password Description....369
Changing The Owner Password....369
Changing The User Passwords....370
Password Lockout Feature....370
MAINTENANCE CLOCK....371
Description....371
Setup....371
Reset....371
MACHINE SIGN TRANSLATIONS....372
MACHINE SIGN TRANSLATIONS....374
Service Schedule (7167998)....374
Warning (7167993)....377
Warning (7169291)....377
Danger (7167989)....377
Danger (7167990)....377
Danger (7167988)....378
Warning (7167994)....379
Warning (7167996)....380
Warning (7168142)....380
Warning (7184346)....381
Danger (7170355)....381
Lift Arm Support Device (7169340)....382
Warning (7168148)....383
Warning (7142141)....384
Warning (7168019)....385
Warning (6737189)....386
SPECIFICATIONS....388
(A770) LOADER SPECIFICATIONS....390
Machine Dimensions....390
Performance....391
Engine....391
Drive System....392
Controls....392
Hydraulic System....393
Electrical System....394
Capacities....394
Tires....394
WARRANTY....396
WARRANTY....398
ALPHABETICAL INDEX....400
6989480 (1-11) - A770 All-Wheel Steer Loader Service Manual....402
MAINTENANCE SAFETY....404
CONTENTS....406
FOREWORD....408
FOREWORD....410
SAFETY INSTRUCTIONS....413
FIRE PREVENTION....415
Maintenance....415
Operation....415
Electrical....415
Hydraulic System....415
Fueling....415
Starting....415
Spark Arrestor Exhaust System....415
Welding And Grinding....416
Fire Extinguishers....416
SERIAL NUMBER LOCATIONS....417
Loader Serial Number....417
Engine Serial Number....417
DELIVERY REPORT....418
LOADER IDENTIFICATION....419
SAFETY & MAINTENANCE....420
LIFTING AND BLOCKING THE LOADER....424
Procedure....424
LIFT ARM SUPPORT DEVICE....426
Installing....426
Removing....427
OPERATOR CAB....428
Description....428
Raising....429
Lowering....430
Cab Door Sensor....431
Special Applications Kit....431
Special Applications Kit Inspection And Maintenance....431
Forestry Door And Window Kit....432
Forestry Door And Window Kit Inspection And Maintenance....432
TRANSPORTING LOADER ON A TRAILER....434
Loading And Unloading....434
Fastening....434
TOWING THE LOADER....436
Procedure....436
REMOTE START TOOL KIT-MEL1563....438
Remote Start Tool - MEL1563....438
Service Tool Harness Communicator - MEL1566....440
Remote Start Procedure....440
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....444
Description....444
Remote Start Tool (Service Tool) - 7003030....445
Loader Service Tool Harness - 6689747....446
Computer Service Tool Harness - 6689746....447
Remote Start Procedure....448
SERVICE SCHEDULE....452
Chart....452
AIR CLEANER SERVICE....454
Replacing Filter Elements....454
ENGINE COOLING SYSTEM....456
Maintenance Platform....456
Cleaning....456
Checking Level....458
Removing And Replacing Coolant....458
FUEL SYSTEM....460
Fuel Specifications....460
Biodiesel Blend Fuel....460
Filling The Fuel Tank....461
Fuel Filter....462
Removing Air From The Fuel System....462
ENGINE LUBRICATION SYSTEM....464
Checking And Adding Engine Oil....464
Engine Oil Chart....464
Removing And Replacing Oil And Filter....465
HYDRAULIC / HYDROSTATIC SYSTEM....466
Checking And Adding Fluid....466
Hydraulic / Hydrostatic Fluid Chart....466
Removing And Replacing Hydraulic Fluid....467
Removing And Replacing Hydraulic / Hydrostatic Filter....469
Removing And Replacing Steering Filter....470
Removing And Replacing Hydraulic Charge Filter....471
Breather Cap....472
FINAL DRIVE TRANSMISSION (CHAINCASE)....474
Checking And Adding Oil....474
Removing And Replacing Oil....474
BOB-TACH (HAND LEVER)....476
Inspection And Maintenance....476
BOB-TACH (POWER)....478
Inspection And Maintenance....478
LUBRICATING THE LOADER....480
Lubrication Locations....480
TIRE MAINTENANCE....484
Wheel Nuts....484
Rotating....484
Mounting....484
SPARK ARRESTER MUFFLER....486
Cleaning Procedure....486
PIVOT PINS....488
Inspection And Maintenance....488
LOADER STORAGE AND RETURN TO SERVICE....490
Storage....490
Return To Service....490
STOPPING THE ENGINE AND LEAVING THE LOADER....492
Procedure....492
EMERGENCY EXIT....494
External Access....494
Rear Window....494
Front Door....494
SEAT BELT....496
Inspection And Maintenance....496
HYDRAULIC SYSTEM....498
HYDRAULIC / HYDROSTATIC SCHEMATICS....502
HYDRAULIC SYSTEM INFORMATION....506
Glossary Of Hydraulic / Hydrostatic Symbols....506
Troubleshooting....510
CYLINDER (LIFT)....512
Testing....512
Removal And Installation....513
Parts Identification....517
Disassembly....518
Assembly....520
CYLINDER (TILT)....524
Testing....524
Removal And Installation....525
Base End Pivot Pin Removal And Installation....526
Parts Identification....527
Disassembly....528
Assembly....530
CYLINDER (BOB-TACH)....534
Testing....534
Removal And Installation....535
Parts Identification....536
Disassembly....537
Assembly....539
CYLINDER (STEERING)....542
Testing....542
Removal And Installation (Front)....544
Removal And Installation (Rear)....547
Parts Identification....550
Disassembly....551
Assembly....552
MAIN RELIEF VALVE....556
Description....556
Testing....557
Adjusting....559
Removal And Installation....559
HYDRAULIC CONTROL VALVE....562
Description....562
Removal And Installation....562
Actuator Removal And Installation (In Loader)....566
Actuator Removal And Installation (Out Of Loader)....568
Identification Chart....571
Mount Bracket Removal And Installation....572
Lift Load Check Valve Removal And Installation....572
Load Check Valve Removal And Installation (Tilt And Auxiliary)....573
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....574
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....574
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....575
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....575
Port Relief Valve Removal And Installation (Auxiliary)....576
Plug Removal And Installation....577
End Cap Block Removal And Installation....578
Lift Spool Removal And Installation....578
Tilt Spool Removal And Installation....582
Auxiliary Spool Removal And Installation....585
Auxiliary Solenoid Removal And Installation....586
Solenoid Removal And Installation....587
Lock Valve Removal And Installation....588
Lift Arm Bypass Orifice Inspection....589
Main Relief Valve Removal And Installation....589
Check Valve Removal And Installation....590
LIFT ARM BYPASS CONTROL VALVE....592
Description....592
Testing....592
Removal And Installation....593
Bracket Removal And Installation....594
Disassembly And Assembly....594
HYDRAULIC PUMP....596
Description....596
Pump Test At Quick Couplers....597
Direct Pump Test (Standard Section)....599
Direct Pump Test (Charge Section)....601
Direct Pump Test (Steering Section)....603
Removal And Installation....605
Hydraulic Pump Startup....607
Parts Identification....608
Disassembly And Assembly....608
HYDRAULIC PUMP (HIGH FLOW)....610
Description....610
Pump Test At Quick Couplers....611
Direct Pump Test (Standard Section)....613
Direct Pump Test (Charge Section)....614
Direct Pump Test (High Flow Section)....616
High Flow Relief Valve Adjustment....618
High Flow Relief Valve Removal And Installation....619
Direct Pump Test (Steering Section)....620
Solenoid Removal And Installation....622
Removal And Installation....623
Hydraulic Pump Startup....625
Parts Identification....626
Disassembly And Assembly....627
HYDRAULIC / HYDROSTATIC FILTERS....628
Description....628
Housing Removal And Installation....629
HYDRAULIC FLUID RESERVOIR....632
Description....632
Removal And Installation....632
Hydraulic Fluid Screen....633
OIL COOLER....634
Description....634
Removal And Installation....634
BUCKET POSITION VALVE....636
Description....636
Solenoid Removal And Installation....636
Solenoid Testing....637
Removal And Installation....637
Disassembly And Assembly....640
REAR AUXILIARY DIVERTER VALVE....642
Description....642
Solenoid Testing....642
Removal And Installation....643
Disassembly And Assembly....644
BOB-TACH (POWER) BLOCK....650
Description....650
Removal And Installation....650
Disassembly And Assembly....652
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....656
Description....656
Removal And Installation....656
Disassembly And Assembly....656
HYDROSTATIC SYSTEM....658
HYDROSTATIC SYSTEM INFORMATION....660
Troubleshooting....660
Description....661
HYDROSTATIC MOTOR (TWO-SPEED)....662
Description....662
Removal And Installation....662
Parts Identification....665
Disassembly....666
Assembly....672
HYDROSTATIC MOTOR CARRIER (SJC)....678
Description....678
Removal And Installation....679
Parts Identification....681
Disassembly....682
Assembly....685
CHARGE PRESSURE....688
Description....688
Testing....689
Sender Removal And Installation....690
Adjusting....691
HYDROSTATIC PUMP (SJC)....692
Description....692
Hydraulic Controller Removal And Installation....693
Removal And Installation....695
Hydrostatic Pump Start Up....697
Parts Identification....698
High Pressure Relief And Bypass Valve....699
Charge Relief Valve....700
Disassembly....701
Inspection....710
Assembly....714
Mechanical Neutral Adjustment....724
Hydraulic Controller Neutral Adjustment....727
DRIVE BELT....730
Belt Adjustment....730
Belt Replacement....731
Stop Adjustment....733
Tensioner Pulley Removal And Installation....734
Tensioner Pulley Disassembly And Assembly....735
TWO-SPEED / BRAKE VALVE....736
Description....736
Valve Block Removal And Installation....737
Valve Block Disassembly And Assembly....739
DRAIN MANIFOLD....742
Description....742
Drain Manifold Removal And Installation....742
DRIVE SYSTEM....744
BRAKE....746
Description....746
STEERING BLOCK....748
Description....748
Identification....749
Removal And Installation....751
Disassembly And Assembly....752
DRIVE COMPONENTS....760
Description....760
Axle Seal Removal And Installation....761
Axle, Sprocket And Bearings Removal And Installation....763
Chain Removal And Installation....768
CHAINCASE....770
Description....770
Front Cover Removal And Installation....770
Center Cover Removal And Installation....771
Rear Cover Removal And Installation....772
HUB....774
Description....774
Removal....774
Installation....777
Disassembly....781
Assembly....784
MAINFRAME....788
SEAT BAR....790
Description....790
Removal And Installation....790
Disassembly And Assembly....791
Compression Spring Disassembly And Assembly....792
OPERATOR CAB....794
Gas Spring Removal And Installation....794
Gas Spring Bracket Disassembly And Assembly....795
Removal And Installation....795
OPERATOR SEAT (SUSPENSION)....798
Removal And Installation....798
Slide Rail Removal And Installation....798
Seat Belt Removal And Installation....799
Lower Cushion Removal....799
Lower Cushion Installation....800
Back Cushion Removal And Installation....800
Shock Removal And Installation....801
3-Point Seat Belt Removal And Installation....801
BOB-TACH (HAND LEVER)....804
Description....804
Removal And Installation....804
Lever And Wedge Disassembly And Assembly....806
Pivot Pin Bushing And Seal Removal And Installation....808
BOB-TACH (POWER)....810
Description....810
Removal And Installation....810
Lever And Wedge Disassembly And Assembly....813
Pivot Pin Bushing And Seal Removal And Installation....814
LIFT ARMS....816
Stabilizer Bar Removal And Installation....816
Link Removal And Installation....817
Removal And Installation....818
REAR GRILLE....822
Removing....822
Installing....822
REAR DOOR (TAILGATE)....824
Removal And Installation....824
Striker Removal And Installation....825
Striker Adjusting....825
Latch Removal And Installation....826
FUEL TANK....828
Removal And Installation....828
Fuel Level Sender Removal And Installation....830
Fuel Fill Screen Removal And Installation....831
FLOOR PAN....832
Floor Pan Removal And Installation....832
CONTROL PANEL....834
Description....834
Removal And Installation....834
JOYSTICK CONTROL....836
Description....836
Joystick Testing....836
Joystick Removal And Installation....837
ACCESS PANEL (INSIDE)....838
Removal And Installation (Left)....838
Removal And Installation (Right)....838
ACCESS PANEL (INSIDE) (SJC)....840
Removal And Installation (Left)....840
Removal And Installation (Right)....840
WINDOW (REAR)....842
Removal And Installation....842
Disassembly And Assembly....842
WINDOW (TOP)....844
Removal And Installation....844
WINDOW (SIDE)....846
Removal And Installation....846
CAB DOOR....848
Description....848
Removal And Installation....848
Disassembly And Assembly....849
Aligning....850
Adjusting....851
Checking Operation....851
ELECTRICAL SYSTEM & ANALYSIS....852
ELECTRICAL SCHEMATICS....856
ELECTRICAL SYSTEM INFORMATION....870
Glossary Of Electrical Symbols....870
Cab Harness Connectors....873
Mainframe Harness Connectors....874
Description....875
Troubleshooting....876
Fuse And Relay Location / Identification....877
Solenoid Testing....879
BATTERY....880
Removal And Installation....880
Servicing....881
Using A Booster Battery (Jump Starting)....882
ALTERNATOR....884
Belt Adjustment....884
Belt Replacement....884
Charging System Inspection....885
Alternator Voltage Testing....886
Low Voltage Testing....886
High Voltage Testing....887
Removal And Installation....888
Parts Identification....889
STARTER....890
Testing....890
Removal And Installation....890
Parts Identification....891
INSTRUMENT PANELS....892
Left Panel....892
Display Screen....894
Right Panel (Standard Key Panel)....894
Right Panel (Keyless Start Panel)....895
Right Panel (Deluxe Instrumentation Panel)....896
Left Switch Panel....898
Right Switch Panel....898
Left Side Lower Panel....899
Right Side Lower Panel....899
Left Panel Removal And Installation....900
Right Panel Removal And Installation....900
Key Switch Disassembly And Assembly....901
Alarm Disassembly And Assembly....901
Left Switch Panel Removal And Installation....902
Right Switch Panel Removal And Installation....902
LIGHTS....904
Front Removal And Installation....904
Rear Removal And Installation....905
Cab Light Removal And Installation....905
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)....906
Description....906
Connector Identification....907
Removal And Installation....913
BOBCAT CONTROLLER (ACS)....914
Description....914
Connector And Wire Identification....915
Removal And Installation....916
BOBCAT CONTROLLER (DRIVE PLUS)....918
Description....918
Connector Identification....919
Removal And Installation....921
SPEED SENSORS....922
Description....922
Testing....922
Removal And Installation....924
DIAGNOSTIC SERVICE CODES....926
Viewing Service Codes....926
Service Codes List....927
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....932
Description....932
Inspecting The BICS? (Engine STOPPED - Key ON)....933
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....933
Inspecting The Seat Bar Sensor (Engine RUNNING)....933
Inspecting The Traction Lock (Engine RUNNING)....933
Inspecting The Lift Arm Bypass Control....933
Inspecting Deactivation Of Lift And Tilt Functions (SJC)....933
Troubleshooting....934
SEAT BAR SENSOR....936
Description....936
Troubleshooting....936
Testing....937
Removal And Installation....938
Bobcat Interlock Control System (BICS?) Circuit Test....941
TRACTION LOCK....944
Description....944
Troubleshooting....945
Inspecting....946
ELECTRICAL / HYDRAULIC CONTROLS (SJC)....948
Identification Chart....948
Description....949
Identification Chart ACD Group 0....950
Identification Chart ACD Group 1....951
Identification Chart ACD Group 2....952
Identification Chart ACD Group 3....953
SERVICE PC (LAPTOP COMPUTER)....954
Connecting Remote Start Tool....954
Connecting Remote Start Tool (Service Tool)....954
CALIBRATION....956
Description....956
Actuator Testing....956
Lift And Tilt Calibration....959
Hydrostatic Pump Calibration....961
STEERING DRIFT COMPENSATION....966
Description....966
Operation....966
FLYWHEEL RPM SENSOR....968
Description....968
Removal....968
Installation....968
CONTROL PANEL SETUP....970
Right Panel Setup (Deluxe Instrumentation Panel)....970
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....972
Password Description....972
Changing The Owner Password....972
Changing The User Passwords....973
Password Lockout Feature....973
PASSWORD SETUP (KEYLESS START PANEL)....974
Password Description....974
Changing The Owner Password....974
Password Lockout Feature....974
MAINTENANCE CLOCK....976
Description....976
Setup....977
Reset....980
BACK-UP ALARM SYSTEM....982
Description....982
Inspecting....982
Troubleshooting....983
Alarm Removal And Installation....984
FRONT HORN....986
Description....986
Inspecting....986
Front Horn Removal And Installation....986
Troubleshooting....987
ENGINE SERVICE....988
ENGINE INFORMATION....992
Description....992
Specifications....993
Torque Values....996
Troubleshooting....996
Engine Removal And Installation....998
Engine Mount Replacement....1005
Compression - Checking....1006
ENGINE SPEED CONTROL (HAND)....1008
Removal And Installation....1008
Disassembly And Assembly....1008
Cable Removal And Installation....1009
ENGINE SPEED CONTROL (FOOT)....1010
Removal And Installation....1010
Disassembly And Assembly....1011
MUFFLER....1014
Removal And Installation....1014
AIR CLEANER....1016
Housing Removal And Installation....1016
ENGINE COOLING SYSTEM....1018
Radiator Removal And Installation....1018
Hydraulic Fan Description....1020
Fan Duct Removal And Installation....1020
Hydraulic Fan Motor Assembly Removal And Installation....1021
Hydraulic Fan Motor Removal And Installation....1021
Hydraulic Fan Motor Disassembly And Assembly....1023
Blower Housing Removal And Installation....1024
Water Pump Removal And Installation....1025
Water Pump Disassembly And Assembly....1025
Thermostat Housing Removal And Installation....1026
Thermostat - Checking....1026
LUBRICATION SYSTEM....1028
Oil Pan Removal And Installation....1028
Oil Pump Removal And Installation....1029
Oil Pump Inspection....1029
Oil Filter Cooler Removal And Installation....1031
Engine Oil Pressure - Testing....1032
FUEL SYSTEM....1034
Fuel Shutoff Solenoid - Checking....1034
Fuel Shutoff Solenoid Removal And Installation....1034
Fuel Injection Pump Assembly Removal....1035
Fuel Injection Pump Assembly Installation....1039
Governor Housing Disassembly And Assembly....1041
Governor Disassembly And Assembly....1043
Fuel Camshaft Removal And Installation....1045
Fuel Injection Pump Removal....1047
Fuel Injection Pump Installation....1050
Injection Pump - Timing....1053
Fuel Injector Removal And Installation....1057
Fuel Injector Nozzle Pressure - Checking....1058
Nozzle Spraying Condition....1059
Valve Seat Tightness....1059
CYLINDER HEAD....1060
Intake Air Heater - Testing....1060
Intake Air Heater Removal And Installation....1060
Valve Clearance Adjustment....1061
Valve Timing - Checking....1063
Cylinder Head Removal And Installation....1064
Cylinder Head Disassembly And Assembly....1066
Cylinder Head - Servicing....1067
Cylinder Head Top Clearance....1067
Valve Guide - Checking....1068
Reconditioning The Valve And Valve Seat....1070
Valve Spring....1072
Valve Tappets....1073
Rocker Arm And Shaft - Checking....1074
Push Rod Alignment - Checking....1074
CRANKSHAFT AND PISTONS....1076
Piston And Connecting Rod Removal And Installation....1076
Piston And Connecting Rod - Servicing....1078
Cylinder Bore - Checking....1082
Connecting Rod Alignment....1083
Crankshaft Gear Removal And Installation....1083
Crankshaft And Bearings Removal....1084
Crankshaft And Bearings Installation....1086
Crankshaft And Bearings - Servicing....1088
CAMSHAFT AND TIMING GEArS....1094
Timing Gearcase Cover Removal And Installation....1094
Timing Gears Backlash - Checking....1095
Idler Gear And Camshaft Removal And Installation....1095
Camshaft - Servicing....1096
Idler Gear And Shaft - Servicing....1098
TURBOCHARGER....1100
Description....1100
Testing....1100
Removal And Installation....1101
FLYWHEEL AND HOUSING....1104
Flywheel Removal And Installation....1104
Ring Gear Removal And Installation....1104
Housing Removal And Installation....1105
EXHAUST GAS RECIRCULATION (EGR) SYSTEM....1106
Description....1106
Testing....1107
Removal And Installation....1110
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....1112
AIR CONDITIONING SYSTEM FLOW....1114
Description....1114
Chart....1115
Components....1116
Safety Equipment....1119
REGULAR MAINTENANCE....1120
Filters....1120
Belt Adjustment....1121
Belt Replacement....1121
Condenser....1121
Air Conditioning Lubrication....1121
Air Conditioning Service Chart....1122
Evaporator / Heater Coil....1123
TROUBLESHOOTING....1124
Blower Motor Does Not Operate....1124
Blower Motor Operates Normally, But Air Flow Is Insufficient....1124
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....1124
The Compressor Does Not Operate At All, Or Operates Improperly....1124
Gauge Pressure Related Troubleshooting....1125
Troubleshooting Tree....1127
Temperature / Pressure Chart....1130
Poor A/C Performance....1132
HVAC Repair And Leaks....1133
Electrical System....1134
Engine Coolant Bypassing The Heater Valve....1140
Heater Valve Not Opening Or Closing....1141
SYSTEM CHARGING AND RECLAMATION....1142
Refrigerant Identification....1142
Reclamation And Charging With Recovery / Charging Unit....1143
COMPRESSOR....1146
Removal And Installation....1146
Oil....1148
Oil Check....1149
CONDENSER....1150
Removal And Installation....1150
RECEIVER / DRIER....1152
Receiver / Drier Removal And Installation....1152
Pressure Relief Valve Removal And Installation....1153
Pressure Switch Removal And Installation....1154
Schrader? Valve Removal And Installation....1155
EVAPORATOR / HEATER UNIT....1156
Removal And Installation....1156
THERMOSTAT....1158
Description....1158
Removal And Installation....1159
EXPANSION VALVE....1160
Removal And Installation....1160
EVAPORATOR COIL....1162
Removal And Installation....1162
HEATER COIL....1164
Removal And Installation....1164
BLOWER FAN....1166
Removal And Installation....1166
Disassembly And Assembly....1166
HEATER VALVE....1170
Removal And Installation....1170
SPECIFICATIONS....1172
(A770) LOADER SPECIFICATIONS....1174
Machine Dimensions....1174
Performance....1175
Engine....1175
Drive System....1176
Controls....1176
Hydraulic System....1177
Electrical System....1178
Capacities....1178
Tires....1178
TORQUE SPECIFICATIONS FOR BOLTS....1180
Torque For General SAE Bolts....1180
Torque For General Metric Bolts....1181
HYDRAULIC CONNECTION SPECIFICATIONS....1182
Straight Thread O-ring Fitting....1182
Flare Fitting....1183
Tubelines And Hoses....1183
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....1184
Specifications....1184
CONVERSIONS....1186
Decimal And Millimeter Equivalent Chart....1186
U.S. To Metric Conversion Chart....1186
ALPHABETICAL INDEX....1188
6989480 (11-12) - A770 All-Wheel Steer Loader Service Manual....1190
MAINTENANCE SAFETY....1192
CONTENTS....1194
FOREWORD....1196
FOREWORD....1198
SAFETY INSTRUCTIONS....1200
FIRE PREVENTION....1202
Maintenance....1202
Operation....1202
Electrical....1202
Hydraulic System....1202
Fueling....1202
Starting....1202
Spark Arrester Exhaust System....1202
Welding And Grinding....1203
Fire Extinguishers....1203
SERIAL NUMBER LOCATIONS....1204
Loader Serial Number....1204
Engine Serial Number....1204
DELIVERY REPORT....1205
LOADER IDENTIFICATION....1206
SAFETY AND MAINTENANCE....1208
LIFTING AND BLOCKING THE LOADER....1212
Procedure....1212
LIFT ARM SUPPORT DEVICE....1214
Installing....1214
Removing....1215
OPERATOR CAB....1216
Description....1216
Raising....1217
Lowering....1218
Cab Door Sensor....1219
Special Applications Kit....1220
Special Applications Kit Inspection And Maintenance....1220
Forestry Door And Window Kit....1220
Forestry Door And Window Kit Inspection And Maintenance....1221
TRANSPORTING THE LOADER ON A TRAILER....1222
Loading And Unloading....1222
Fastening....1222
TOWING THE LOADER....1224
Procedure....1224
REMOTE START TOOL KIT-MEL1563....1226
Remote Start Tool - MEL1563....1226
Service Tool Harness Communicator - MEL1566....1228
Remote Start Procedure....1228
REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....1232
Description....1232
Remote Start Tool (Service Tool) - 7022042....1233
Loader Service Tool Harness - 6689747....1234
Computer Service Tool Harness - 6689746....1235
Remote Start Procedure....1236
SERVICE SCHEDULE....1240
Chart....1240
AIR CLEANER SERVICE....1242
Replacing Filter Elements....1242
ENGINE COOLING SYSTEM....1244
Maintenance Platform....1244
Cleaning....1244
Checking Level....1246
Removing And Replacing Coolant....1246
FUEL SYSTEM....1248
Fuel Specifications....1248
Biodiesel Blend Fuel....1248
Filling The Fuel Tank....1249
Fuel Filter....1250
Removing Air From The Fuel System....1250
ENGINE LUBRICATION SYSTEM....1252
Checking And Adding Engine Oil....1252
Engine Oil Chart....1252
Removing And Replacing Oil And Filter....1253
HYDRAULIC / HYDROSTATIC SYSTEM....1256
Checking And Adding Fluid....1256
Hydraulic / Hydrostatic Fluid Chart....1256
Removing And Replacing Hydraulic Fluid....1257
Removing And Replacing Hydraulic / Hydrostatic Filter....1259
Removing And Replacing Steering Filter....1260
Removing And Replacing Hydraulic Charge Filter....1261
Breather Cap....1262
FINAL DRIVE TRANSMISSION (CHAINCASE)....1264
Checking And Adding Oil....1264
Removing And Replacing Oil....1265
BOB-TACH (HAND LEVER)....1266
Inspection And Maintenance....1266
BOB-TACH (POWER)....1268
Inspection And Maintenance....1268
LUBRICATING THE LOADER....1270
Lubrication Locations....1270
TIRE MAINTENANCE....1274
Wheel Nuts....1274
Rotating....1274
Mounting....1274
SPARK ARRESTER MUFFLER....1276
Cleaning Procedure....1276
PIVOT PINS....1278
Inspection And Maintenance....1278
LOADER STORAGE AND RETURN TO SERVICE....1280
Storage....1280
Return To Service....1280
STOPPING THE ENGINE AND LEAVING THE LOADER....1282
Procedure....1282
EMERGENCY EXIT....1284
External Access....1284
Rear Window....1284
Front Door....1284
SEAT BELT....1286
Inspection And Maintenance....1286
HYDRAULIC SYSTEM....1288
HYDRAULIC / HYDROSTATIC SCHEMATICS....1292
HYDRAULIC SYSTEM INFORMATION....1300
Glossary Of Hydraulic / Hydrostatic Symbols....1300
Troubleshooting....1304
CYLINDER (LIFT)....1306
Testing....1306
Removal And Installation....1307
Parts Identification....1311
Disassembly....1312
Assembly....1314
CYLINDER (TILT)....1318
Testing....1318
Removal And Installation....1319
Base End Pivot Pin Removal And Installation....1320
Parts Identification....1321
Disassembly....1322
Assembly....1324
CYLINDER (BOB-TACH)....1328
Testing....1328
Removal And Installation....1329
Parts Identification....1330
Disassembly....1331
Assembly....1333
CYLINDER (STEERING)....1336
Testing....1336
Removal And Installation (Front)....1338
Removal And Installation (Rear)....1341
Parts Identification....1344
Disassembly....1345
Assembly....1346
MAIN RELIEF VALVE (EARLY MODELS)....1350
Description....1350
Testing....1351
Adjusting....1353
Removal And Installation....1353
MAIN RELIEF VALVE (LATE MODELS)....1356
Description....1356
Testing....1357
Main Relief Valve Adjustment....1359
Main Relief Valve Removal And Installation....1359
Auxiliary Relief Valve Adjustment....1360
Auxiliary Relief Valve Removal And Installation....1361
HYDRAULIC CONTROL VALVE (EARLY MODELS)....1362
Description....1362
Removal And Installation....1362
Actuator Removal And Installation (In Loader)....1366
Actuator Removal And Installation (Out Of Loader)....1368
Identification Chart....1371
Mount Bracket Removal And Installation....1372
Lift Load Check Valve Removal And Installation....1372
Load Check Valve Removal And Installation (Tilt And Auxiliary)....1373
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....1374
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....1374
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....1375
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....1375
Port Relief Valve Removal And Installation (Auxiliary)....1376
Plug Removal And Installation....1377
End Cap Block Removal And Installation....1378
Lift Spool Removal And Installation....1378
Tilt Spool Removal And Installation....1382
Auxiliary Spool Removal And Installation....1385
Auxiliary Solenoid Removal And Installation....1386
Solenoid Removal And Installation....1387
Lock Valve Removal And Installation....1388
Lift Arm Bypass Orifice Inspection....1389
Main Relief Valve Removal And Installation....1389
Check Valve Removal And Installation....1390
HYDRAULIC CONTROL VALVE (LATE MODELS)....1392
Description....1392
Removal And Installation....1392
Actuator Removal And Installation (In Loader)....1397
Actuator Removal And Installation (Out Of Loader)....1398
Identification Chart....1401
Mount Bracket Removal And Installation....1402
Lift Load Check Valve Removal And Installation....1402
Load Check Valve Removal And Installation (Tilt And Auxiliary)....1403
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....1404
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....1404
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....1405
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....1405
Port Relief Valve Removal And Installation....1406
Plug Removal And Installation....1408
End Cap Block Removal And Installation....1409
Lift Spool Removal And Installation....1409
Lift Spool Disassembly And Assembly....1411
Tilt Spool Removal And Installation....1412
Auxiliary Spool Removal And Installation....1414
Auxiliary Solenoid Removal And Installation....1415
Solenoid Removal And Installation....1416
Lock Valve Removal And Installation....1417
Lift Arm Bypass Orifice Removal And Installation....1419
Main Relief Valve Removal And Installation....1419
Auxiliary Relief Valve Removal And Installation....1420
Check Valve Removal And Installation....1420
LIFT ARM BYPASS CONTROL VALVE....1422
Description....1422
Testing....1422
Removal And Installation....1423
Bracket Removal And Installation....1424
Disassembly And Assembly....1424
HYDRAULIC PUMP....1426
Description....1426
Pump Test At Quick Couplers....1427
Direct Pump Test (Standard Section)....1429
Direct Pump Test (Charge Section)....1431
Direct Pump Test (Steering Section)....1433
Removal And Installation....1435
Hydraulic Pump Startup....1437
Parts Identification....1438
Disassembly And Assembly....1439
HYDRAULIC PUMP (HIGH FLOW)....1440
Description....1440
Pump Test At Quick Couplers....1441
Direct Pump Test (Standard Section)....1443
Direct Pump Test (Charge Section)....1444
Direct Pump Test (High Flow Section)....1446
High Flow Relief Valve Adjustment....1448
High Flow Relief Valve Removal And Installation....1449
Direct Pump Test (Steering Section)....1450
Solenoid Removal And Installation....1452
Removal And Installation....1453
Hydraulic Pump Startup....1455
Parts Identification....1456
Disassembly And Assembly....1457
HYDRAULIC / HYDROSTATIC FILTERS....1458
Description....1458
Housing Removal And Installation....1459
HYDRAULIC FLUID RESERVOIR....1462
Description....1462
Removal And Installation....1462
Hydraulic Fluid Screen....1463
OIL COOLER....1464
Description....1464
Removal And Installation....1464
BUCKET POSITION VALVE....1466
Description....1466
Solenoid Removal And Installation....1466
Solenoid Testing....1467
Removal And Installation....1467
Disassembly And Assembly....1470
REAR AUXILIARY DIVERTER VALVE....1472
Description....1472
Solenoid Testing....1472
Removal And Installation....1473
Disassembly And Assembly....1474
BOB-TACH (POWER) BLOCK....1480
Description....1480
Removal And Installation....1480
Disassembly And Assembly....1482
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....1492
Description....1492
Removal And Installation....1492
Disassembly And Assembly....1492
HYDROSTATIC SYSTEM....1494
HYDROSTATIC SYSTEM INFORMATION....1496
Troubleshooting....1496
Description....1497
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3P611001 - A3P612349 AND A3P711001 - A3P712199)....1498
Description....1498
Removal And Installation....1498
Parts Identification....1501
Disassembly....1502
Assembly....1508
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3P612350 & ABOVE AND A3P712200 & ABOVE)....1514
Description....1514
Removal And Installation....1514
Parts Identification....1517
Disassembly....1518
Assembly....1524
HYDROSTATIC MOTOR CARRIER....1530
Description....1530
Removal And Installation....1531
Parts Identification....1533
Disassembly....1534
Assembly....1537
CHARGE PRESSURE....1540
Description....1540
Testing....1541
Sender Removal And Installation....1542
Adjusting....1543
HYDROSTATIC PUMP....1544
Description....1544
Hydraulic Controller Removal And Installation....1545
Removal And Installation....1547
Hydrostatic Pump Start Up....1549
Parts Identification....1550
High Pressure Relief And Bypass Valve....1551
Charge Relief Valve....1552
Disassembly....1553
Inspection....1562
Assembly....1566
Mechanical Neutral Adjustment....1576
Hydraulic Controller Neutral Adjustment....1579
DRIVE BELT....1582
Belt Adjustment....1582
Belt Replacement....1583
Stop Adjustment....1585
Tensioner Pulley Removal And Installation....1586
Tensioner Pulley Disassembly And Assembly....1587
TWO-SPEED / BRAKE VALVE (S/N A3P611001 - A3P612349 AND A3P711001 - A3P712199)....1588
Description....1588
Valve Block Removal And Installation....1589
Valve Block Disassembly And Assembly....1591
TWO-SPEED / BRAKE VALVE (S/N A3P612350 & ABOVE AND A3P712200 & ABOVE)....1594
Description....1594
Valve Block Removal And Installation....1595
Valve Block Disassembly And Assembly....1597
DRAIN MANIFOLD....1600
Description....1600
Drain Manifold Removal And Installation....1600
DRIVE SYSTEM....1602
BRAKE....1604
Description....1604
STEERING BLOCK....1606
Description....1606
Identification....1607
Removal And Installation....1609
Disassembly And Assembly....1610
DRIVE COMPONENTS....1618
Description....1618
Axle Seal Removal And Installation....1619
Axle, Sprocket And Bearings Removal And Installation....1621
Chain Removal And Installation....1626
CHAINCASE....1628
Description....1628
Front Cover Removal And Installation....1628
Center Cover Removal And Installation....1629
Rear Cover Removal And Installation....1630
HUB....1632
Description....1632
Removal....1632
Installation....1635
Disassembly....1639
Assembly....1642
MAINFRAME....1646
SEAT BAR....1650
Description....1650
Removal And Installation....1650
Disassembly And Assembly....1651
Compression Spring Disassembly And Assembly....1652
OPERATOR CAB....1654
Gas Spring Removal And Installation....1654
Gas Spring Bracket Disassembly And Assembly....1655
Removal And Installation....1655
OPERATOR SEAT (SUSPENSION)....1658
Removal And Installation....1658
Slide Rail Removal And Installation....1658
Seat Belt Removal And Installation....1659
Lower Cushion Removal....1659
Lower Cushion Installation....1660
Back Cushion Removal And Installation....1660
Shock Removal And Installation....1661
3-Point Seat Belt Removal And Installation....1661
BOB-TACH (HAND LEVER)....1664
Description....1664
Removal And Installation....1664
Lever And Wedge Disassembly And Assembly....1666
Pivot Pin Bushing And Seal Removal And Installation....1668
BOB-TACH (POWER)....1670
Description....1670
Removal And Installation....1670
Lever And Wedge Disassembly And Assembly....1673
Pivot Pin Bushing And Seal Removal And Installation....1674
LIFT ARMS....1676
Stabilizer Bar Removal And Installation....1676
Link Removal And Installation....1677
Removal And Installation....1678
REAR GRILLE....1682
Removing....1682
Installing....1682
REAR DOOR (TAILGATE)....1684
Removal And Installation....1684
Striker Removal And Installation....1685
Striker Adjusting....1685
Latch Removal And Installation (Early Models)....1686
Latch Removal And Installation (Later Models)....1687
FUEL TANK....1688
Removal And Installation....1688
Fuel Level Sender Removal And Installation....1690
Fuel Fill Screen Removal And Installation....1691
FLOOR PAN....1692
Floor Pan Removal And Installation....1692
CONTROL PANEL....1694
Description....1694
Removal And Installation....1694
JOYSTICK CONTROL....1696
Description....1696
Joystick Testing....1696
Joystick Removal And Installation....1697
ACCESS PANEL (INSIDE)....1698
Removal And Installation (Left)....1698
Removal And Installation (Right)....1698
WINDOW (REAR)....1700
Removal And Installation....1700
Disassembly And Assembly....1700
WINDOW (TOP)....1702
Removal And Installation....1702
WINDOW (SIDE)....1704
Removal And Installation....1704
CAB DOOR....1706
Description....1706
Removal And Installation....1706
Disassembly And Assembly....1707
Aligning....1708
Adjusting....1709
Checking Operation....1709
ARMREST....1710
Description....1710
Removal And Installation....1711
Disassembly And Assembly....1712
LEFT SIDE LOWER PANEL....1714
Removal And Installation....1714
Disassembly And Assembly....1716
RIGHT SIDE LOWER PANEL....1718
Removal And Installation....1718
Disassembly And Assembly....1719
HEADLINER....1722
Removal And Installation....1722
ELECTRICAL SYSTEM AND ANALYSIS....1724
ELECTRICAL SCHEMATICS....1728
ELECTRICAL SYSTEM INFORMATION....1760
Glossary Of Electrical Symbols....1760
Cab Harness Connectors....1763
Mainframe Harness Connectors....1764
Description....1765
Troubleshooting....1766
Fuse And Relay Location / Identification....1767
Solenoid Testing....1769
BATTERY....1770
Removal And Installation....1770
Servicing....1771
Using A Booster Battery (Jump Starting)....1772
ALTERNATOR....1774
Belt Adjustment....1774
Belt Replacement....1774
Charging System Inspection....1775
Alternator Voltage Testing....1776
Low Voltage Testing....1776
High Voltage Testing....1777
Removal And Installation....1778
Parts Identification....1779
STARTER....1780
Testing....1780
Removal And Installation....1780
Parts Identification....1781
INSTRUMENT PANELS....1782
Left Panel (Earlier Models)....1782
Left Panel (Later Models)....1784
Display Screen....1786
Right Panel (Standard Key Panel)....1786
Right Panel (Keyless Start Panel)....1787
Right Panel (Deluxe Instrumentation Panel)....1788
Left Switch Panel....1790
Right Switch Panel....1790
Left Side Lower Panel....1791
Right Side Lower Panel....1791
Left Panel Removal And Installation....1792
Right Panel Removal And Installation....1792
Key Switch Disassembly And Assembly....1793
Alarm Disassembly And Assembly....1793
Left Switch Panel Removal And Installation....1794
Right Switch Panel Removal And Installation....1794
LIGHTS....1796
Front Removal And Installation....1796
Rear Removal And Installation....1797
Cab Light Removal And Installation....1797
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)....1798
Description....1798
Connector Identification....1799
Removal And Installation....1805
BOBCAT CONTROLLER (ACS)....1806
Description....1806
Connector And Wire Identification....1807
Removal And Installation....1808
BOBCAT CONTROLLER (DRIVE PLUS)....1810
Description....1810
Connector Identification....1811
Removal And Installation....1813
SENSORS (SPEED)....1814
Description....1814
Testing....1814
Removal And Installation....1816
SENSORS (WHEEL POSITION)....1818
Description....1818
Wheel Alignment (Field Adjustment)....1819
Testing....1820
Sensor Removal And Installation....1822
Wheel Alignment (Field Adjustment With Service Analyzer)....1824
Wheel Alignment (Calibration)....1828
DIAGNOSTIC SERVICE CODES....1832
Viewing Service Codes....1832
Service Codes List....1833
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....1840
Description....1840
Inspecting The BICS? (Engine STOPPED - Key ON)....1841
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....1841
Inspecting The Seat Bar Sensor (Engine RUNNING)....1841
Inspecting The Traction Lock (Engine RUNNING)....1841
Inspecting The Lift Arm Bypass Control....1841
Inspecting Deactivation Of Lift And Tilt Functions....1841
Troubleshooting....1842
SEAT BAR SENSOR....1844
Description....1844
Troubleshooting....1844
Testing....1845
Removal And Installation....1846
Bobcat Interlock Control System (BICS?) Circuit Test....1849
TRACTION LOCK....1852
Description....1852
Troubleshooting....1853
Inspecting....1854
ELECTRICAL / HYDRAULIC CONTROLS....1856
Identification Chart....1856
Description....1857
Identification Chart ACD Group 0....1858
Identification Chart ACD Group 1....1859
Identification Chart ACD Group 2....1860
Identification Chart ACD Group 3....1861
SERVICE PC (LAPTOP COMPUTER)....1862
Connecting Remote Start Tool....1862
Connecting Remote Start Tool (Service Tool)....1862
CALIBRATION....1864
Description....1864
Actuator Testing....1864
Lift And Tilt Calibration....1867
Hydrostatic Pump Calibration....1869
STEERING DRIFT COMPENSATION....1874
Description....1874
Operation....1874
FLYWHEEL RPM SENSOR....1876
Description....1876
Removal....1876
Installation....1876
CONTROL PANEL SETUP....1878
Right Panel Setup (Deluxe Instrumentation Panel)....1878
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....1882
Password Description....1882
Changing The Owner Password....1882
Changing The User Passwords....1883
Password Lockout Feature....1883
PASSWORD SETUP (KEYLESS START PANEL)....1884
Password Description....1884
Changing The Owner Password....1884
Password Lockout Feature....1884
MAINTENANCE CLOCK....1886
Description....1886
Setup....1887
Reset....1890
BACK-UP ALARM SYSTEM....1892
Description....1892
Inspecting....1892
Troubleshooting....1893
Alarm Removal And Installation....1894
FRONT HORN....1896
Description....1896
Inspecting....1896
Removal And Installation....1896
Troubleshooting....1897
ENGINE SERVICE....1898
ENGINE INFORMATION....1902
Description....1902
Specifications....1903
Torque Values....1906
Troubleshooting....1906
Engine Removal And Installation....1908
Engine Mount Replacement....1915
Compression - Checking....1916
ENGINE SPEED CONTROL (HAND)....1918
Removal And Installation....1918
Disassembly And Assembly....1918
Cable Removal And Installation....1919
ENGINE SPEED CONTROL (FOOT)....1920
Removal And Installation....1920
Disassembly And Assembly....1921
MUFFLER....1924
Removal And Installation....1924
AIR CLEANER....1926
Housing Removal And Installation....1926
ENGINE COOLING SYSTEM....1928
Radiator Removal And Installation....1928
Hydraulic Fan Description....1930
Fan Duct Removal And Installation....1930
Hydraulic Fan Motor Assembly Removal And Installation....1931
Hydraulic Fan Motor Removal And Installation....1931
Hydraulic Fan Motor Disassembly And Assembly....1933
Blower Housing Removal And Installation....1934
Water Pump Removal And Installation....1935
Water Pump Disassembly And Assembly....1935
Thermostat Housing Removal And Installation....1936
Thermostat - Checking....1936
LUBRICATION SYSTEM....1938
Oil Pan Removal And Installation....1938
Oil Pump Removal And Installation....1939
Oil Pump Inspection....1939
Oil Filter Cooler Removal And Installation....1941
Engine Oil Pressure - Testing....1942
FUEL SYSTEM....1944
Fuel Shutoff Solenoid - Checking....1944
Fuel Shutoff Solenoid Removal And Installation....1944
Fuel Injection Pump Assembly Removal....1945
Fuel Injection Pump Assembly Installation....1949
Governor Housing Disassembly And Assembly....1951
Governor Disassembly And Assembly....1953
Fuel Camshaft Removal And Installation....1955
Fuel Injection Pump Removal....1957
Fuel Injection Pump Installation....1960
Injection Pump - Timing....1962
Fuel Injector Removal And Installation....1966
Fuel Injector Nozzle Pressure - Checking....1968
Nozzle Spraying Condition....1968
Valve Seat Tightness....1969
CYLINDER HEAD....1970
Intake Air Heater - Testing....1970
Intake Air Heater Removal And Installation....1970
Valve Clearance Adjustment....1971
Valve Timing - Checking....1973
Cylinder Head Removal And Installation....1974
Cylinder Head Disassembly And Assembly....1976
Cylinder Head - Servicing....1977
Cylinder Head Top Clearance....1977
Valve Guide - Checking....1978
Reconditioning The Valve And Valve Seat....1980
Valve Spring....1982
Valve Tappets....1983
Rocker Arm And Shaft - Checking....1984
Push Rod Alignment - Checking....1984
CRANKSHAFT AND PISTONS....1986
Piston And Connecting Rod Removal And Installation....1986
Piston And Connecting Rod - Servicing....1988
Cylinder Bore - Checking....1992
Connecting Rod Alignment....1993
Crankshaft Gear Removal And Installation....1993
Crankshaft And Bearings Removal....1994
Crankshaft And Bearings Installation....1996
Crankshaft And Bearings - Servicing....1998
CAMSHAFT AND TIMING GEARS....2004
Timing Gearcase Cover Removal And Installation....2004
Timing Gears Backlash - Checking....2005
Idler Gear And Camshaft Removal And Installation....2005
Camshaft - Servicing....2006
Idler Gear And Shaft - Servicing....2008
TURBOCHARGER....2010
Description....2010
Testing....2010
Removal And Installation....2011
FLYWHEEL AND HOUSING....2014
Flywheel Removal And Installation....2014
Ring Gear Removal And Installation....2014
Housing Removal And Installation....2015
EXHAUST GAS RECIRCULATION (EGR) SYSTEM....2016
Description....2016
Testing....2017
Removal And Installation....2020
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....2022
AIR CONDITIONING SYSTEM FLOW....2024
Description....2024
Chart....2025
Components....2026
Safety Equipment....2029
REGULAR MAINTENANCE....2030
Filters....2030
Belt Adjustment....2031
Belt Replacement....2031
Condenser....2031
Air Conditioning Lubrication....2031
Air Conditioning Service Chart....2032
Evaporator / Heater Coil....2033
TROUBLESHOOTING....2034
Blower Motor Does Not Operate....2034
Blower Motor Operates Normally, But Air Flow Is Insufficient....2034
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....2034
The Compressor Does Not Operate At All, Or Operates Improperly....2034
Gauge Pressure Related Troubleshooting....2035
Troubleshooting Tree....2037
Temperature / Pressure Chart....2040
Poor A/C Performance....2042
HVAC Repair And Leaks....2043
Electrical System....2044
Engine Coolant Bypassing The Heater Valve....2050
Heater Valve Not Opening Or Closing....2051
SYSTEM CHARGING AND RECLAMATION....2052
Refrigerant Identification....2052
Reclamation And Charging With Recovery / Charging Unit....2053
COMPRESSOR....2056
Removal And Installation....2056
Oil....2058
Oil Check....2059
CONDENSER....2060
Removal And Installation....2060
RECEIVER / DRIER....2062
Receiver / Drier Removal And Installation....2062
Pressure Relief Valve Removal And Installation....2063
Pressure Switch Removal And Installation....2064
Schrader? Valve Removal And Installation....2065
EVAPORATOR / HEATER UNIT....2066
Removal And Installation....2066
THERMOSTAT....2068
Description....2068
Removal And Installation....2069
EXPANSION VALVE....2070
Removal And Installation....2070
EVAPORATOR COIL....2072
Removal And Installation....2072
HEATER COIL....2074
Removal And Installation....2074
BLOWER FAN....2076
Removal And Installation....2076
Disassembly And Assembly....2076
HEATER VALVE....2080
Removal And Installation....2080
SPECIFICATIONS....2082
(A770) LOADER SPECIFICATIONS....2084
Machine Dimensions....2084
Performance....2085
Engine....2085
Drive System....2086
Controls....2086
Hydraulic System....2087
Electrical System....2088
Capacities....2088
Tires....2088
TORQUE SPECIFICATION FOR BOLTS....2090
Torque For General SAE Bolts....2090
Torque For General Metric Bolts....2091
HYDRAULIC CONNECTION SPECIFICATIONS....2092
Straight Thread O-ring Fitting....2092
Flare Fitting....2093
Tubelines And Hoses....2093
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....2094
Specifications....2094
CONVERSIONS....2096
Decimal And Millimeter Equivalent Chart....2096
U.S. To Metric Conversion Chart....2096
ALPHABETICAL INDEX....2098
SERVICE MANUAL REVISION....2102
Revision No: A770 - 1....2102
6990114 (3-11) - A770 All-Wheel Steer Loader Operation & Maintenance Manual....2104
OPERATOR SAFETY WARNINGS....2106
CONTENTS....2108
FOREWORD....2110
BOBCAT COMPANY IS IS0 9001 CERTIFIED....2112
REGULAR MAINTENANCE ITEMS....2112
SERIAL NUMBER LOCATIONS....2113
Loader Serial Number....2113
Engine Serial Number....2113
DELIVERY REPORT....2113
LOADER IDENTIFICATION....2114
FEATURES, ACCESSORIES AND ATTACHMENTS....2115
Standard Items....2115
Options And Accessories....2115
Buckets Available....2116
Attachments....2116
High-Flow Attachments....2116
Special Applications Kit....2117
Special Applications Kit Inspection And Maintenance....2117
Forestry Door And Window Kit....2118
Forestry Door And Window Kit Inspection And Maintenance....2118
SAFETY & TRAINING RESOURCES....2120
SAFETY INSTRUCTIONS....2122
Before Operation....2122
Safe Operation Is The Operator?s Responsibility....2123
Safe Operation Needs A Qualified Operator....2123
Avoid Silica Dust....2124
FIRE PREVENTION....2124
Maintenance....2124
Operation....2124
Electrical....2124
Hydraulic System....2125
Fueling....2125
Starting....2125
Spark Arrestor Exhaust System....2125
Welding And Grinding....2125
Fire Extinguishers....2125
PUBLICATIONS AND TRAINING RESOURCES....2126
MACHINE SIGNS (DECALS)....2127
No-Text Safety Signs....2130
OPERATING INSTRUCTIONS....2138
INSTRUMENT PANEL IDENTIFICATION....2142
Overview....2142
Left Panel....2143
Display Screen....2145
Right Panel (Standard Key Panel)....2145
Right Panel (Keyless Start Panel)....2146
Right Panel (Deluxe Instrumentation Panel)....2147
Left Switch Panel....2149
Right Switch Panel....2149
Left Side Lower Panel....2150
Right Side Lower Panel....2150
Radio....2151
CONTROL IDENTIFICATION....2153
Standard Controls....2153
OPERATOR CAB....2154
Description....2154
Cab Light....2154
Door Operation....2154
Front Wiper....2155
Side Windows....2155
SEAT BAR RESTRAINT SYSTEM....2156
Operation....2156
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....2157
Operation....2157
LIFT ARM BYPASS CONTROL....2158
Operation....2158
PARKING BRAKE....2158
Operation....2158
STEERING MODE SELECTION....2159
Operation....2159
TRACTION LOCK OVERRIDE....2159
Operation....2159
ENGINE SPEED CONTROL....2160
Operation....2160
EMERGENCY EXIT....2161
External Access....2161
Rear Window....2161
Front Door....2161
BACK-UP ALARM SYSTEM....2163
Description....2163
Operation....2163
DRIVING AND STEERING THE LOADER....2164
All-Wheel Steer Mode....2164
Stopping The Loader (All-Wheel Steer Mode)....2164
Skid-Steer Mode....2165
Stopping The Loader (Skid-Steer Mode)....2165
TWO-SPEED CONTROL....2166
Description....2166
Operation....2166
SPEED MANAGEMENT....2167
Operation....2167
Changing The Factory Default Setting....2168
DRIVE RESPONSE....2169
Description....2169
Operation....2169
STEERING DRIFT COMPENSATION....2171
Description....2171
Operation....2171
HYDRAULIC CONTROLS....2173
Description....2173
Lift Arm Operation....2173
Lift Arm Float Position....2173
Tilt Operation....2173
Hydraulic Bucket Positioning....2174
FRONT Auxiliary Hydraulics Operation....2174
FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....2175
FRONT Auxiliary Hydraulics Operation (REVERSE CONTINUOUS FLOW)....2175
REAR Auxiliary Hydraulics Operation....2176
High-Flow Hydraulics Operation....2177
Quick Couplers....2177
Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....2178
ATTACHMENT CONTROL DEVICE (ACD)....2179
Description....2179
DAILY INSPECTION....2180
Daily Inspection And Maintenance....2180
PRE-STARTING PROCEDURE....2182
Entering The Loader....2182
Operation & Maintenance Manual And Operator?s Handbook Locations....2182
Seat Adjustment....2183
Joystick Position Adjustment....2184
Seat Belt Adjustment....2184
Seat Bar....2184
STARTING THE ENGINE....2185
Standard Key Panel....2185
Keyless Start Panel....2187
Deluxe Instrumentation Panel....2189
Cold Temperature Starting....2191
Warming The Hydraulic / Hydrostatic System....2191
MONITORING THE DISPLAY PANELS....2192
Left Panel....2192
Warning And Shutdown....2192
STOPPING THE ENGINE AND LEAVING THE LOADER....2193
Procedure....2193
COUNTERWEIGHTS....2194
Description....2194
Effect On The Loader And Loader Operation....2194
When To Consider Using Counterweights....2194
When To Consider Removing Counterweights....2194
Accessories That Affect Machine Weight....2194
ATTACHMENTS....2195
Choosing The Correct Bucket....2195
Pallet Fork....2195
Installing And Removing The Attachment (Hand Lever Bob-Tach)....2196
Installing And Removing The Attachment (Power Bob-Tach)....2198
OPERATING PROCEDURE....2202
Inspect The Work Area....2202
Basic Operating Instructions....2202
Driving On Public Roads....2202
Operating With A Full Bucket....2203
Operating With An Empty Bucket....2203
Filling And Emptying The Bucket....2204
Leveling The Ground Using Float....2205
Digging And Filling A Hole....2206
TOWING THE LOADER....2207
Procedure....2207
LIFTING THE LOADER....2207
Single-Point Lift....2207
Four-Point Lift....2208
TRANSPORTING THE LOADER ON A TRAILER....2209
Loading And Unloading....2209
Fastening....2209
PREVENTIVE MAINTENANCE....2210
MAINTENANCE SAFETY....2214
SERVICE SCHEDULE....2216
Chart....2216
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....2217
Inspecting The BICS? (Engine STOPPED - Key ON)....2217
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....2217
Inspecting The Seat Bar Sensor (Engine RUNNING)....2217
Inspecting The Traction Lock (Engine RUNNING)....2217
Inspecting The Lift Arm Bypass Control....2217
Inspecting Deactivation Of Lift And Tilt Functions....2217
SEAT BAR RESTRAINT SYSTEM....2218
Description....2218
Inspecting....2218
Maintaining....2218
SEAT BELT....2219
Inspection And Maintenance....2219
LIFT ARM SUPPORT DEVICE....2220
Installing....2220
Removing....2221
BACK-UP ALARM SYSTEM....2222
Description....2222
Inspecting....2222
OPERATOR CAB....2223
Description....2223
Raising....2223
Lowering....2224
Cab Door Sensor....2225
REAR DOOR (TAILGATE)....2226
Opening And Closing....2226
Adjusting....2226
REAR GRILLE....2227
Removing....2227
Installing....2227
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....2228
Cleaning And Maintenance....2228
Filters....2228
Evaporator / Heater Coil....2228
Condenser....2229
Air Conditioning Lubrication....2229
Troubleshooting....2229
AIR CLEANER SERVICE....2229
Replacing Filter Elements....2229
FUEL SYSTEM....2231
Fuel Specifications....2231
Biodiesel Blend Fuel....2231
Filling The Fuel Tank....2232
Fuel Filter....2233
Removing Air From The Fuel System....2233
ENGINE LUBRICATION SYSTEM....2234
Checking And Adding Engine Oil....2234
Engine Oil Chart....2234
Removing And Replacing Oil And Filter....2235
ENGINE COOLING SYSTEM....2236
Maintenance Platform....2236
Cleaning....2236
Checking Level....2238
Removing And Replacing Coolant....2238
ELECTRICAL SYSTEM....2239
Description....2239
Fuse And Relay Location / Identification....2239
Battery Maintenance....2241
Using A Booster Battery (Jump Starting)....2242
Removing And Installing Battery....2243
HYDRAULIC / HYDROSTATIC SYSTEM....2244
Checking And Adding Fluid....2244
Hydraulic / Hydrostatic Fluid Chart....2244
Removing And Replacing Hydraulic Fluid....2245
Removing And Replacing Hydraulic / Hydrostatic Filter....2247
Removing And Replacing Steering Filter....2248
Removing And Replacing Hydraulic Charge Filter....2249
Breather Cap....2250
SPARK ARRESTER MUFFLER....2251
Cleaning Procedure....2251
TIRE MAINTENANCE....2252
Wheel Nuts....2252
Rotating....2252
Mounting....2252
FINAL DRIVE TRANSMISSION (CHAINCASE)....2253
Checking And Adding Oil....2253
Removing And Replacing Oil....2253
ALTERNATOR BELT....2254
Belt Adjustment....2254
Belt Replacement....2254
AIR CONDITIONING BELT....2255
Belt Adjustment....2255
Belt Replacement....2255
DRIVE BELT....2256
Belt Adjustment....2256
Stop Adjustment....2256
Belt Replacement....2256
WHEEL ALIGNMENT....2258
Wheel Position Sensors....2258
Aligning The Wheels....2258
LUBRICATING THE LOADER....2259
Lubrication Locations....2259
PIVOT PINS....2262
Inspection And Maintenance....2262
BOB-TACH (HAND LEVER)....2263
Inspection And Maintenance....2263
BOB-TACH (POWER)....2264
Inspection And Maintenance....2264
LOADER STORAGE AND RETURN TO SERVICE....2265
Storage....2265
Return To Service....2265
SYSTEM SETUP & ANALYSIS....2266
DIAGNOSTIC SERVICE CODES....2268
Viewing Service Codes....2268
Service Codes List....2269
CONTROL PANEL SETUP....2274
Right Panel Setup (Deluxe Instrumentation Panel)....2274
PASSWORD SETUP (KEYLESS START PANEL)....2276
Password Description....2276
Changing The Owner Password....2276
Password Lockout Feature....2276
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....2277
Password Description....2277
Changing The Owner Password....2277
Changing The User Passwords....2278
Password Lockout Feature....2278
MAINTENANCE CLOCK....2279
Description....2279
Setup....2279
Reset....2279
SPECIFICATIONS....2280
(A770) LOADER SPECIFICATIONS....2282
Machine Dimensions....2282
Performance....2283
Engine....2283
Drive System....2284
Controls....2284
Hydraulic System....2285
Electrical System....2286
Capacities....2286
Tires....2286
WARRANTY....2288
WARRANTY....2290
ALPHABETICAL INDEX....2292
6990115 (09-11) - A770 All-Wheel Steer Loader Service Manual....2294
MAINTENANCE SAFETY....2296
CONTENTS....2298
FOREWORD....2300
FOREWORD....2302
SAFETY INSTRUCTIONS....2305
FIRE PREVENTION....2307
Maintenance....2307
Operation....2307
Electrical....2307
Hydraulic System....2307
Fueling....2307
Starting....2307
Spark Arrester Exhaust System....2307
Welding And Grinding....2308
Fire Extinguishers....2308
SERIAL NUMBER LOCATIONS....2309
Loader Serial Number....2309
Engine Serial Number....2309
DELIVERY REPORT....2310
LOADER IDENTIFICATION....2311
SAFETY & MAINTENANCE....2312
LIFTING AND BLOCKING THE LOADER....2316
Procedure....2316
LIFT ARM SUPPORT DEVICE....2318
Installing....2318
Removing....2319
OPERATOR CAB....2320
Description....2320
Raising....2321
Lowering....2322
Cab Door Sensor....2323
Special Applications Kit....2323
Special Applications Kit Inspection And Maintenance....2323
Forestry Door And Window Kit....2324
Forestry Door And Window Kit Inspection And Maintenance....2324
TRANSPORTING LOADER ON A TRAILER....2326
Loading And Unloading....2326
Fastening....2326
TOWING THE LOADER....2328
Procedure....2328
REMOTE START TOOL KIT-MEL1563....2330
Remote Start Tool - MEL1563....2330
Service Tool Harness Communicator - MEL1566....2332
Remote Start Procedure....2332
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....2336
Description....2336
Remote Start Tool (Service Tool) - 7003030....2337
Loader Service Tool Harness - 6689747....2338
Computer Service Tool Harness - 6689746....2339
Remote Start Procedure....2340
SERVICE SCHEDULE....2344
Chart....2344
AIR CLEANER SERVICE....2346
Replacing Filter Elements....2346
ENGINE COOLING SYSTEM....2348
Maintenance Platform....2348
Cleaning....2348
Checking Level....2350
Removing And Replacing Coolant....2350
FUEL SYSTEM....2352
Fuel Specifications....2352
Biodiesel Blend Fuel....2352
Filling The Fuel Tank....2353
Fuel Filter....2354
Removing Air From The Fuel System....2354
ENGINE LUBRICATION SYSTEM....2356
Checking And Adding Engine Oil....2356
Engine Oil Chart....2356
Removing And Replacing Oil And Filter....2357
HYDRAULIC / HYDROSTATIC SYSTEM....2358
Checking And Adding Fluid....2358
Hydraulic / Hydrostatic Fluid Chart....2358
Removing And Replacing Hydraulic Fluid....2359
Removing And Replacing Hydraulic / Hydrostatic Filter....2361
Removing And Replacing Steering Filter....2362
Removing And Replacing Hydraulic Charge Filter....2363
Breather Cap....2364
FINAL DRIVE TRANSMISSION (CHAINCASE)....2366
Checking And Adding Oil....2366
Removing And Replacing Oil....2366
BOB-TACH (HAND LEVER)....2368
Inspection And Maintenance....2368
BOB-TACH (POWER)....2370
Inspection And Maintenance....2370
LUBRICATING THE LOADER....2372
Lubrication Locations....2372
TIRE MAINTENANCE....2376
Wheel Nuts....2376
Rotating....2376
Mounting....2376
SPARK ARRESTER MUFFLER....2378
Cleaning Procedure....2378
PIVOT PINS....2380
Inspection And Maintenance....2380
LOADER STORAGE AND RETURN TO SERVICE....2382
Storage....2382
Return To Service....2382
STOPPING THE ENGINE AND LEAVING THE LOADER....2384
Procedure....2384
EMERGENCY EXIT....2386
External Access....2386
Rear Window....2386
Front Door....2386
SEAT BELT....2388
Inspection And Maintenance....2388
HYDRAULIC SYSTEM....2390
HYDRAULIC / HYDROSTATIC SCHEMATICS....2394
HYDRAULIC SYSTEM INFORMATION....2398
Glossary Of Hydraulic / Hydrostatic Symbols....2398
Troubleshooting....2402
CYLINDER (LIFT)....2404
Testing....2404
Removal And Installation....2405
Parts Identification....2409
Disassembly....2410
Assembly....2412
CYLINDER (TILT)....2416
Testing....2416
Removal And Installation....2417
Base End Pivot Pin Removal And Installation....2418
Parts Identification....2419
Disassembly....2420
Assembly....2422
CYLINDER (BOB-TACH)....2426
Testing....2426
Removal And Installation....2427
Parts Identification....2428
Disassembly....2429
Assembly....2431
CYLINDER (STEERING)....2434
Testing....2434
Removal And Installation (Front)....2436
Removal And Installation (Rear)....2439
Parts Identification....2442
Disassembly....2443
Assembly....2444
MAIN RELIEF VALVE....2448
Description....2448
Testing....2449
Adjusting....2451
Removal And Installation....2451
HYDRAULIC CONTROL VALVE....2454
Description....2454
Removal And Installation....2454
Actuator Removal And Installation (In Loader)....2458
Actuator Removal And Installation (Out Of Loader)....2460
Identification Chart....2463
Mount Bracket Removal And Installation....2464
Lift Load Check Valve Removal And Installation....2464
Load Check Valve Removal And Installation (Tilt And Auxiliary)....2465
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....2466
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....2466
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....2467
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....2467
Port Relief Valve Removal And Installation (Auxiliary)....2468
Plug Removal And Installation....2469
End Cap Block Removal And Installation....2470
Lift Spool Removal And Installation....2470
Tilt Spool Removal And Installation....2474
Auxiliary Spool Removal And Installation....2477
Auxiliary Solenoid Removal And Installation....2478
Solenoid Removal And Installation....2479
Lock Valve Removal And Installation....2480
Lift Arm Bypass Orifice Inspection....2481
Main Relief Valve Removal And Installation....2481
Check Valve Removal And Installation....2482
LIFT ARM BYPASS CONTROL VALVE....2484
Description....2484
Testing....2484
Removal And Installation....2485
Bracket Removal And Installation....2486
Disassembly And Assembly....2486
HYDRAULIC PUMP....2488
Description....2488
Pump Test At Quick Couplers....2489
Direct Pump Test (Standard Section)....2491
Direct Pump Test (Charge Section)....2493
Direct Pump Test (Steering Section)....2495
Removal And Installation....2497
Hydraulic Pump Startup....2499
Parts Identification....2500
Disassembly And Assembly....2501
HYDRAULIC PUMP (HIGH FLOW)....2502
Description....2502
Pump Test At Quick Couplers....2503
Direct Pump Test (Standard Section)....2505
Direct Pump Test (Charge Section)....2506
Direct Pump Test (High Flow Section)....2508
High Flow Relief Valve Adjustment....2510
High Flow Relief Valve Removal And Installation....2511
Direct Pump Test (Steering Section)....2512
Solenoid Removal And Installation....2514
Removal And Installation....2515
Hydraulic Pump Startup....2517
Parts Identification....2518
Disassembly And Assembly....2519
HYDRAULIC / HYDROSTATIC FILTERS....2520
Description....2520
Housing Removal And Installation....2521
HYDRAULIC FLUID RESERVOIR....2524
Description....2524
Removal And Installation....2524
Hydraulic Fluid Screen....2525
OIL COOLER....2526
Description....2526
Removal And Installation....2526
BUCKET POSITION VALVE....2528
Description....2528
Solenoid Removal And Installation....2528
Solenoid Testing....2529
Removal And Installation....2529
Disassembly And Assembly....2532
REAR AUXILIARY DIVERTER VALVE....2534
Description....2534
Solenoid Testing....2534
Removal And Installation....2535
Disassembly And Assembly....2536
BOB-TACH (POWER) BLOCK....2542
Description....2542
Removal And Installation....2542
Disassembly And Assembly....2544
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....2548
Description....2548
Removal And Installation....2548
Disassembly And Assembly....2548
HYDROSTATIC SYSTEM....2550
HYDROSTATIC SYSTEM INFORMATION....2552
Troubleshooting....2552
Description....2553
HYDROSTATIC MOTOR (TWO-SPEED)....2554
Description....2554
Removal And Installation....2554
Parts Identification....2557
Disassembly....2558
Assembly....2564
HYDROSTATIC MOTOR CARRIER (SJC)....2570
Description....2570
Removal And Installation....2571
Parts Identification....2573
Disassembly....2574
Assembly....2577
CHARGE PRESSURE....2580
Description....2580
Testing....2581
Sender Removal And Installation....2582
Adjusting....2583
HYDROSTATIC PUMP (SJC)....2584
Description....2584
Hydraulic Controller Removal And Installation....2585
Removal And Installation....2587
Hydrostatic Pump Start Up....2589
Parts Identification....2590
High Pressure Relief And Bypass Valve....2591
Charge Relief Valve....2592
Disassembly....2593
Inspection....2602
Assembly....2606
Mechanical Neutral Adjustment....2616
Hydraulic Controller Neutral Adjustment....2619
DRIVE BELT....2622
Belt Adjustment....2622
Belt Replacement....2622
Stop Adjustment....2624
Tensioner Pulley Removal And Installation....2625
Tensioner Pulley Disassembly And Assembly....2626
TWO-SPEED / BRAKE VALVE....2628
Description....2628
Valve Block Removal And Installation....2629
Valve Block Disassembly And Assembly....2631
DRAIN MANIFOLD....2634
Description....2634
Drain Manifold Removal And Installation....2634
DRIVE SYSTEM....2636
BRAKE....2638
Description....2638
STEERING BLOCK....2640
Description....2640
Identification....2641
Removal And Installation....2643
Disassembly And Assembly....2644
DRIVE COMPONENTS....2652
Description....2652
Axle Seal Removal And Installation....2653
Axle, Sprocket And Bearings Removal And Installation....2655
Chain Removal And Installation....2660
CHAINCASE....2662
Description....2662
Front Cover Removal And Installation....2662
Center Cover Removal And Installation....2663
Rear Cover Removal And Installation....2664
HUB....2666
Description....2666
Removal....2666
Installation....2669
Disassembly....2673
Assembly....2676
MAINFRAME....2680
SEAT BAR....2684
Description....2684
Removal And Installation....2684
Disassembly And Assembly....2685
Compression Spring Disassembly And Assembly....2686
OPERATOR CAB....2688
Gas Spring Removal And Installation....2688
Gas Spring Bracket Disassembly And Assembly....2689
Removal And Installation....2689
OPERATOR SEAT (SUSPENSION)....2692
Removal And Installation....2692
Slide Rail Removal And Installation....2692
Seat Belt Removal And Installation....2693
Lower Cushion Removal....2693
Lower Cushion Installation....2694
Back Cushion Removal And Installation....2694
Shock Removal And Installation....2695
3-Point Seat Belt Removal And Installation....2695
BOB-TACH (HAND LEVER)....2698
Description....2698
Removal And Installation....2698
Lever And Wedge Disassembly And Assembly....2700
Pivot Pin Bushing And Seal Removal And Installation....2702
BOB-TACH (POWER)....2704
Description....2704
Removal And Installation....2704
Lever And Wedge Disassembly And Assembly....2707
Pivot Pin Bushing And Seal Removal And Installation....2708
LIFT ARMS....2710
Stabilizer Bar Removal And Installation....2710
Link Removal And Installation....2711
Removal And Installation....2712
REAR GRILLE....2716
Removing....2716
Installing....2716
REAR DOOR (TAILGATE)....2718
Removal And Installation....2718
Striker Removal And Installation....2719
Striker Adjusting....2719
Latch Removal And Installation....2720
FUEL TANK....2722
Removal And Installation....2722
Fuel Level Sender Removal And Installation....2724
Fuel Fill Screen Removal And Installation....2725
FUEL TANK (AUXILIARY)....2726
Removal And Installation....2726
FLOOR PAN....2728
Floor Pan Removal And Installation....2728
CONTROL PANEL....2730
Description....2730
Removal And Installation....2730
JOYSTICK CONTROL....2732
Description....2732
Joystick Testing....2732
Joystick Removal And Installation....2733
ACCESS PANEL (INSIDE) (SJC)....2734
Removal And Installation (Left)....2734
Removal And Installation (Right)....2734
WINDOW (REAR)....2736
Removal And Installation....2736
Disassembly And Assembly....2736
WINDOW (TOP)....2738
Removal And Installation....2738
WINDOW (SIDE)....2740
Removal And Installation....2740
CAB DOOR....2742
Description....2742
Removal And Installation....2742
Disassembly And Assembly....2743
Aligning....2744
Adjusting....2745
Checking Operation....2745
ARMREST....2746
Description....2746
Removal And Installation....2747
Disassembly And Assembly....2748
LEFT SIDE LOWER PANEL....2750
Removal And Installation....2750
Disassembly And Assembly....2752
RIGHT SIDE LOWER PANEL....2754
Removal And Installation....2754
Disassembly And Assembly....2755
HEADLINER....2758
Removal And Installation....2758
ELECTRICAL SYSTEM & ANALYSIS....2760
ELECTRICAL SCHEMATICS....2764
ELECTRICAL SYSTEM INFORMATION....2782
Glossary Of Electrical Symbols....2782
Cab Harness Connectors....2785
Mainframe Harness Connectors....2786
Description....2787
Troubleshooting....2788
Fuse And Relay Location / Identification....2789
Solenoid Testing....2791
BATTERY....2792
Removal And Installation....2792
Servicing....2793
Using A Booster Battery (Jump Starting)....2794
ALTERNATOR....2796
Belt Adjustment....2796
Belt Replacement....2796
Charging System Inspection....2797
Alternator Voltage Testing....2798
Low Voltage Testing....2798
High Voltage Testing....2799
Removal And Installation....2800
Parts Identification....2801
STARTER....2802
Testing....2802
Removal And Installation....2802
Parts Identification....2803
INSTRUMENT PANELS....2804
Left Panel....2804
Display Screen....2806
Right Panel (Standard Key Panel)....2806
Right Panel (Keyless Start Panel)....2807
Right Panel (Deluxe Instrumentation Panel)....2808
Left Switch Panel....2810
Right Switch Panel....2810
Left Side Lower Panel....2811
Right Side Lower Panel....2811
Left Panel Removal And Installation....2812
Right Panel Removal And Installation....2812
Key Switch Disassembly And Assembly....2813
Alarm Disassembly And Assembly....2813
Left Switch Panel Removal And Installation....2814
Right Switch Panel Removal And Installation....2814
LIGHTS....2816
Front Removal And Installation....2816
Rear Removal And Installation....2817
Cab Light Removal And Installation....2817
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)....2818
Description....2818
Connector Identification....2819
Removal And Installation....2825
BOBCAT CONTROLLER (ACS)....2826
Description....2826
Connector And Wire Identification....2827
Removal And Installation....2828
BOBCAT CONTROLLER (DRIVE PLUS)....2830
Description....2830
Connector Identification....2831
Removal And Installation....2833
SPEED SENSORS....2834
Description....2834
Testing....2834
Removal And Installation....2836
DIAGNOSTIC SERVICE CODES....2838
Viewing Service Codes....2838
Service Codes List....2839
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....2844
Description....2844
Inspecting The BICS? (Engine STOPPED - Key ON)....2845
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....2845
Inspecting The Seat Bar Sensor (Engine RUNNING)....2845
Inspecting The Traction Lock (Engine RUNNING)....2845
Inspecting The Lift Arm Bypass Control....2845
Inspecting Deactivation Of Lift And Tilt Functions (SJC)....2845
Troubleshooting....2846
SEAT BAR SENSOR....2848
Description....2848
Troubleshooting....2848
Testing....2849
Removal And Installation....2850
Bobcat Interlock Control System (BICS?) Circuit Test....2853
TRACTION LOCK....2856
Description....2856
Troubleshooting....2857
Inspecting....2858
ELECTRICAL / HYDRAULIC CONTROLS (SJC)....2860
Identification Chart....2860
Description....2861
Identification Chart ACD Group 0....2862
Identification Chart ACD Group 1....2863
Identification Chart ACD Group 2....2864
Identification Chart ACD Group 3....2865
SERVICE PC (LAPTOP COMPUTER)....2866
Connecting Remote Start Tool....2866
Connecting Remote Start Tool (Service Tool)....2866
CALIBRATION....2868
Description....2868
Actuator Testing....2868
Lift And Tilt Calibration....2871
Hydrostatic Pump Calibration....2873
STEERING DRIFT COMPENSATION....2878
Description....2878
Operation....2878
FLYWHEEL RPM SENSOR....2880
Description....2880
Removal....2880
Installation....2880
CONTROL PANEL SETUP....2882
Right Panel Setup (Deluxe Instrumentation Panel)....2882
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....2884
Password Description....2884
Changing The Owner Password....2884
Changing The User Passwords....2885
Password Lockout Feature....2885
PASSWORD SETUP (KEYLESS START PANEL)....2886
Password Description....2886
Changing The Owner Password....2886
Password Lockout Feature....2886
MAINTENANCE CLOCK....2888
Description....2888
Setup....2889
Reset....2892
BACK-UP ALARM SYSTEM....2894
Description....2894
Inspecting....2894
Troubleshooting....2895
Alarm Removal And Installation....2896
FRONT HORN....2898
Description....2898
Inspecting....2898
Front Horn Removal And Installation....2898
Troubleshooting....2899
ENGINE SERVICE....2900
ENGINE INFORMATION....2904
Description....2904
Specifications....2905
Troubleshooting....2908
Engine Removal And Installation....2910
Engine Mount Replacement....2917
Compression - Checking....2918
ENGINE SPEED CONTROL (HAND)....2920
Removal And Installation....2920
Disassembly And Assembly....2920
Cable Removal And Installation....2921
ENGINE SPEED CONTROL (FOOT)....2922
Removal And Installation....2922
Disassembly And Assembly....2923
MUFFLER....2926
Removal And Installation....2926
AIR CLEANER....2928
Housing Removal And Installation....2928
ENGINE COOLING SYSTEM....2930
Radiator Removal And Installation....2930
Hydraulic Fan Description....2932
Fan Duct Removal And Installation....2932
Hydraulic Fan Motor Assembly Removal And Installation....2933
Hydraulic Fan Motor Removal And Installation....2933
Hydraulic Fan Motor Disassembly And Assembly....2935
Blower Housing Removal And Installation....2936
Water Pump Removal And Installation....2937
Water Pump Disassembly And Assembly....2937
Thermostat Housing Removal And Installation....2938
Thermostat - Checking....2938
LUBRICATION SYSTEM....2940
Oil Pan Removal And Installation....2940
Oil Pump Removal And Installation....2941
Oil Pump Inspection....2941
Oil Filter Cooler Removal And Installation....2943
Engine Oil Pressure - Testing....2944
FUEL SYSTEM....2946
Fuel Shutoff Solenoid - Checking....2946
Fuel Shutoff Solenoid Removal And Installation....2946
Fuel Injection Pump Assembly Removal....2947
Fuel Injection Pump Assembly Installation....2950
Governor Housing Disassembly And Assembly....2953
Governor Disassembly And Assembly....2955
Fuel Camshaft Removal And Installation....2957
Fuel Injection Pump Removal....2959
Fuel Injection Pump Installation....2962
Injection Pump - Timing....2965
Fuel Injector Removal And Installation....2968
Fuel Injector Nozzle Pressure - Checking....2969
Nozzle Spraying Condition....2970
Valve Seat Tightness....2970
CYLINDER HEAD....2972
Intake Air Heater - Testing....2972
Intake Air Heater Removal And Installation....2972
Valve Clearance Adjustment....2973
Valve Timing - Checking....2975
Cylinder Head Removal And Installation....2976
Cylinder Head Disassembly And Assembly....2979
Cylinder Head - Servicing....2979
Cylinder Head Top Clearance....2980
Valve Guide - Checking....2981
Reconditioning The Valve And Valve Seat....2983
Valve Spring....2985
Valve Tappets....2986
Rocker Arm And Shaft - Checking....2987
Push Rod Alignment - Checking....2987
CRANKSHAFT AND PISTONS....2988
Piston And Connecting Rod Removal And Installation....2988
Piston And Connecting Rod - Servicing....2990
Cylinder Bore - Checking....2994
Connecting Rod Alignment....2995
Crankshaft Gear Removal And Installation....2995
Crankshaft And Bearings Removal....2996
Crankshaft And Bearings Installation....2998
Crankshaft And Bearings - Servicing....3000
CAMSHAFT AND TIMING GEARS....3006
Timing Gearcase Cover Removal And Installation....3006
Timing Gears Backlash - Checking....3007
Idler Gear And Camshaft Removal And Installation....3007
Camshaft - Servicing....3008
Idler Gear And Shaft - Servicing....3010
TURBOCHARGER....3012
Description....3012
Testing....3012
Removal And Installation....3014
FLYWHEEL AND HOUSING....3016
Flywheel Removal And Installation....3016
Ring Gear Removal And Installation....3016
Housing Removal And Installation....3017
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....3018
AIR CONDITIONING SYSTEM FLOW....3020
Description....3020
Chart....3021
Components....3022
Safety Equipment....3025
REGULAR MAINTENANCE....3026
Filters....3026
Compressor Drive Belt Adjustment....3027
Compressor Drive Belt Replacement....3027
Condenser....3027
Air Conditioning Lubrication....3027
Air Conditioning Service Chart....3028
Evaporator / Heater Coil....3029
TROUBLESHOOTING....3030
Blower Motor Does Not Operate....3030
Blower Motor Operates Normally, But Air Flow Is Insufficient....3030
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....3030
The Compressor Does Not Operate At All, Or Operates Improperly....3030
Gauge Pressure Related Troubleshooting....3031
Troubleshooting Tree....3033
Temperature / Pressure Chart....3036
Poor A/C Performance....3038
HVAC Repair And Leaks....3039
Electrical System....3040
Engine Coolant Bypassing The Heater Valve....3046
Heater Valve Not Opening Or Closing....3047
SYSTEM CHARGING AND RECLAMATION....3048
Refrigerant Identification....3048
Reclamation And Charging With Recovery / Charging Unit....3049
COMPRESSOR....3052
Removal And Installation....3052
Oil....3054
Oil Check....3055
CONDENSER....3056
Removal And Installation....3056
RECEIVER / DRIER....3058
Receiver / Drier Removal And Installation....3058
Pressure Relief Valve Removal And Installation....3059
Pressure Switch Removal And Installation....3060
Schrader? Valve Removal And Installation....3061
EVAPORATOR / HEATER UNIT....3062
Removal And Installation....3062
THERMOSTAT....3064
Description....3064
Removal And Installation....3065
EXPANSION VALVE....3066
Removal And Installation....3066
EVAPORATOR COIL....3068
Removal And Installation....3068
HEATER COIL....3070
Removal And Installation....3070
BLOWER FAN....3072
Removal And Installation....3072
Disassembly And Assembly....3072
HEATER VALVE....3076
Removal And Installation....3076
SPECIFICATIONS....3078
(A770) LOADER SPECIFICATIONS....3080
Machine Dimensions....3080
Performance....3081
Engine....3081
Drive System....3082
Controls....3082
Hydraulic System....3083
Electrical System....3084
Capacities....3084
Tires....3084
TORQUE SPECIFICATIONS FOR BOLTS....3086
Torque For General SAE Bolts....3086
Torque For General Metric Bolts....3087
HYDRAULIC CONNECTION SPECIFICATIONS....3088
Straight Thread O-ring Fitting....3088
Flare Fitting....3089
Tubelines And Hoses....3089
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....3090
Specifications....3090
CONVERSIONS....3092
Decimal And Millimeter Equivalent Chart....3092
U.S. To Metric Conversion Chart....3092
ALPHABETICAL INDEX....3094
6990245 (06-12) - A770 All-Wheel Steer Loader Service Manual....3096
MAINTENANCE SAFETY....3098
CONTENTS....3100
FOREWORD....3102
FOREWORD....3104
SAFETY INSTRUCTIONS....3106
FIRE PREVENTION....3108
Maintenance....3108
Operation....3108
Electrical....3108
Hydraulic System....3108
Fueling....3108
Starting....3108
Spark Arrester Exhaust System....3108
Welding And Grinding....3109
Fire Extinguishers....3109
SERIAL NUMBER LOCATIONS....3110
Loader Serial Number....3110
Engine Serial Number....3110
DELIVERY REPORT....3111
LOADER IDENTIFICATION....3112
SAFETY AND MAINTENANCE....3114
LIFTING AND BLOCKING THE LOADER....3118
Procedure....3118
LIFT ARM SUPPORT DEVICE....3120
Description....3120
Installing....3120
Removing....3121
OPERATOR CAB....3122
Description....3122
Raising....3122
Lowering....3123
Cab Door Sensor....3124
Special Applications Kit....3125
Special Applications Kit Inspection And Maintenance....3125
Forestry Door And Window Kit....3125
Forestry Door And Window Kit Inspection And Maintenance....3126
TRANSPORTING LOADER ON A TRAILER....3128
Loading And Unloading....3128
Fastening....3128
TOWING THE LOADER....3130
Procedure....3130
REMOTE START TOOL KIT-MEL1563....3132
Remote Start Tool - MEL1563....3132
Service Tool Harness Communicator - MEL1566....3134
Remote Start Procedure....3134
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....3138
Description....3138
Remote Start Tool (Service Tool) - 7003030....3139
Loader Service Tool Harness - 6689747....3140
Computer Service Tool Harness - 6689746....3141
Remote Start Procedure....3142
DIAGMASTER (SERVICE TOOL) KIT - 7024161....3146
Diagmaster (Service Tool)....3146
DST-i LED Table....3147
DST-i Operation Status And Display Specification....3147
Diagmaster (Service Tool) Procedure....3148
SERVICE SCHEDULE....3152
Maintenance Intervals....3152
ENGINE AIR CLEANER....3154
Replacing Filter Elements....3154
ENGINE COOLING SYSTEM....3156
Maintenance Platform....3156
Cleaning....3156
Checking And Adding Coolant....3158
Removing And Replacing Coolant....3159
FUEL SYSTEM....3160
Fuel Specifications....3160
Biodiesel Blend Fuel....3160
Filling The Fuel Tank....3161
Fuel Filter....3162
Removing Air From The Fuel System....3163
ENGINE LUBRICATION SYSTEM....3164
Checking And Adding Engine Oil....3164
Engine Oil Chart....3164
Removing And Replacing Oil And Filter....3165
Removing And Replacing Crankcase Ventilation Filter....3166
HYDRAULIC / HYDROSTATIC SYSTEM....3168
Checking And Adding Fluid....3168
Hydraulic / Hydrostatic Fluid Chart....3168
Removing And Replacing Hydraulic Fluid....3169
Removing And Replacing Hydraulic / Hydrostatic Filter....3171
Removing And Replacing Steering Filter....3172
Removing And Replacing Hydraulic Charge Filter....3173
FINAL DRIVE TRANSMISSION (CHAINCASE)....3174
Checking And Adding Fluid....3174
Removing And Replacing Fluid....3174
BOB-TACH (HAND LEVER)....3176
Inspection And Maintenance....3176
BOB-TACH (POWER)....3178
Inspection And Maintenance....3178
LUBRICATING THE LOADER....3180
Lubrication Locations....3180
TIRE MAINTENANCE....3184
Wheel Nuts....3184
Rotating....3184
Mounting....3184
PIVOT PINS....3186
Inspection And Maintenance....3186
LOADER STORAGE AND RETURN TO SERVICE....3188
Storage....3188
Return To Service....3188
STOPPING THE ENGINE AND LEAVING THE LOADER....3190
Procedure....3190
EMERGENCY EXIT....3192
Rear Window....3192
External Access....3192
Front Door....3192
SEAT BELT....3194
Inspection And Maintenance....3194
HYDRAULIC SYSTEM....3196
HYDRAULIC / HYDROSTATIC SCHEMATICS....3200
HYDRAULIC SYSTEM INFORMATION....3208
Glossary Of Hydraulic / Hydrostatic Symbols....3208
Troubleshooting....3212
CYLINDER (LIFT)....3214
Testing....3214
Removal And Installation....3215
Parts Identification....3219
Disassembly....3220
Assembly....3222
CYLINDER (TILT)....3226
Testing....3226
Removal And Installation....3227
Base End Pivot Pin Removal And Installation....3228
Parts Identification....3229
Disassembly....3230
Assembly....3232
CYLINDER (BOB-TACH)....3236
Testing....3236
Removal And Installation....3237
Parts Identification....3238
Disassembly....3239
Assembly....3241
CYLINDER (STEERING)....3244
Testing....3244
Removal And Installation (Front)....3246
Removal And Installation (Rear)....3249
Parts Identification....3252
Disassembly....3253
Assembly....3254
MAIN RELIEF VALVE (EARLY MODELS)....3258
Description....3258
Testing....3259
Adjusting....3261
Removal And Installation....3261
MAIN RELIEF VALVE (LATE MODELS)....3264
Description....3264
Testing....3265
Main Relief Valve Adjustment....3267
Main Relief Valve Removal And Installation....3267
Auxiliary Relief Valve Adjustment....3268
Auxiliary Relief Valve Removal And Installation....3269
HYDRAULIC CONTROL VALVE (EARLY MODELS)....3270
Description....3270
Removal And Installation....3270
Actuator Removal And Installation (In Loader)....3275
Actuator Removal And Installation (Out Of Loader)....3276
Identification Chart....3279
Mount Bracket Removal And Installation....3280
Lift Load Check Valve Removal And Installation....3280
Load Check Valve Removal And Installation (Tilt And Auxiliary)....3281
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....3282
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....3282
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....3283
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....3283
Port Relief Valve Removal And Installation (Auxiliary)....3284
Plug Removal And Installation....3285
End Cap Block Removal And Installation....3286
Lift Spool Removal And Installation....3286
Tilt Spool Removal And Installation....3290
Tilt Spool Disassembly And Assembly....3291
Auxiliary Spool Removal And Installation....3293
Auxiliary Solenoid Removal And Installation....3294
Solenoid Removal And Installation....3295
Lock Valve Removal And Installation....3296
Lift Arm Bypass Orifice Inspection....3297
Main Relief Valve Removal And Installation....3297
Check Valve Removal And Installation....3298
HYDRAULIC CONTROL VALVE (LATE MODELS)....3300
Description....3300
Removal And Installation....3300
Actuator Removal And Installation (In Loader)....3305
Actuator Removal And Installation (Out Of Loader)....3306
Identification Chart....3309
Mount Bracket Removal And Installation....3310
Lift Load Check Valve Removal And Installation....3310
Load Check Valve Removal And Installation (Tilt And Auxiliary)....3311
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....3312
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....3312
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....3313
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....3313
Port Relief Valve Removal And Installation....3314
Plug Removal And Installation....3316
End Cap Block Removal And Installation....3317
Lift Spool Removal And Installation....3317
Lift Spool Disassembly And Assembly....3319
Tilt Spool Removal And Installation....3320
Auxiliary Spool Removal And Installation....3322
Auxiliary Solenoid Removal And Installation....3323
Solenoid Removal And Installation....3324
Lock Valve Removal And Installation....3325
Lift Arm Bypass Orifice Removal And Installation....3327
Main Relief Valve Removal And Installation....3327
Auxiliary Relief Valve Removal And Installation....3328
Check Valve Removal And Installation....3328
LIFT ARM BYPASS CONTROL VALVE....3330
Description....3330
Testing....3330
Removal And Installation....3331
Bracket Removal And Installation....3332
Disassembly And Assembly....3332
HYDRAULIC PUMP....3334
Description....3334
Pump Test At Quick Couplers....3335
Direct Pump Test (Standard Section)....3337
Direct Pump Test (Charge Section)....3339
Direct Pump Test (Steering Section)....3341
Removal And Installation....3343
Hydraulic Pump Startup....3345
Parts Identification....3346
Disassembly And Assembly....3347
HYDRAULIC PUMP (HIGH FLOW)....3348
Description....3348
Pump Test At Quick Couplers....3349
Direct Pump Test (Standard Section)....3351
Direct Pump Test (Charge Section)....3352
Direct Pump Test (High Flow Section)....3354
High Flow Relief Valve Adjustment....3356
High Flow Relief Valve Removal And Installation....3357
Direct Pump Test (Steering Section)....3358
Solenoid Removal And Installation....3360
Removal And Installation....3361
Hydraulic Pump Startup....3363
Parts Identification....3364
Disassembly And Assembly....3365
HYDRAULIC / HYDROSTATIC FILTERS....3366
Description....3366
Housing Removal And Installation....3367
HYDRAULIC FLUID RESERVOIR....3370
Description....3370
Removal And Installation....3370
Hydraulic Fluid Screen....3371
OIL COOLER....3372
Description....3372
Removal And Installation....3372
BUCKET POSITION VALVE....3374
Description....3374
Solenoid Removal And Installation....3374
Solenoid Testing....3376
Removal And Installation....3377
Disassembly And Assembly....3379
REAR AUXILIARY DIVERTER VALVE....3382
Description....3382
Solenoid Testing....3382
Removal And Installation....3383
Disassembly And Assembly....3384
BOB-TACH (POWER) BLOCK....3390
Description....3390
Removal And Installation....3390
Disassembly And Assembly....3392
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....3402
Description....3402
Removal And Installation....3402
Disassembly And Assembly....3402
HYDROSTATIC SYSTEM....3404
HYDROSTATIC SYSTEM INFORMATION....3406
Troubleshooting....3406
Description....3407
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N ATDW11599 & BELOW)....3408
Description....3408
Removal And Installation....3408
Parts Identification....3411
Disassembly....3412
Assembly....3418
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N ATDW11600 AND ATDY11001 & ABOVE)....3424
Description....3424
Removal And Installation....3424
Parts Identification....3427
Disassembly....3428
Assembly....3434
HYDROSTATIC MOTOR CARRIER....3440
Description....3440
Removal And Installation....3441
Parts Identification....3443
Disassembly....3444
Assembly....3446
CHARGE PRESSURE....3448
Description....3448
Testing....3449
Sender Removal And Installation....3450
Adjusting....3451
HYDROSTATIC PUMP....3452
Description....3452
Hydraulic Controller Removal And Installation....3453
Removal And Installation....3455
Hydrostatic Pump Startup....3456
Parts Identification....3457
High Pressure Relief And Bypass Valve....3458
Charge Relief Valve....3459
Disassembly....3460
Inspection....3469
Assembly....3473
Mechanical Neutral Adjustment....3483
Hydraulic Controller Neutral Adjustment....3486
DRIVE BELT....3490
Belt Adjustment....3490
Stop Adjustment....3490
Belt Replacement....3491
Tensioner Pulley Removal And Installation....3493
Tensioner Pulley Disassembly And Assembly....3494
TWO-SPEED / BRAKE VALVE (S/N ATDW11599 & BELOW)....3496
Description....3496
Valve Block Removal And Installation....3497
Valve Block Disassembly And Assembly....3499
TWO-SPEED / BRAKE VALVE (S/N ATDW11600 & ABOVE AND ATDY11001 & ABOVE)....3502
Description....3502
Valve Block Removal And Installation....3503
Valve Block Disassembly And Assembly....3505
DRAIN MANIFOLD....3508
Description....3508
Drain Manifold Removal And Installation....3508
DRIVE SYSTEM....3510
BRAKE....3512
Description....3512
STEERING BLOCK....3514
Description....3514
Identification....3515
Removal And Installation....3517
Disassembly And Assembly....3518
DRIVE COMPONENTS....3526
Description....3526
Axle Seal Removal And Installation....3527
Axle, Sprocket And Bearings Removal And Installation....3529
Chain Removal And Installation....3534
CHAINCASE....3536
Description....3536
Front Cover Removal And Installation....3536
Center Cover Removal And Installation....3537
Rear Cover Removal And Installation....3538
HUB....3540
Description....3540
Removal....3540
Installation....3543
Disassembly....3547
Assembly....3550
MAINFRAME....3554
SEAT BAR....3558
Description....3558
Removal And Installation....3558
Disassembly And Assembly....3559
Compression Spring Disassembly And Assembly....3560
OPERATOR CAB....3562
Gas Spring Removal And Installation....3562
Gas Spring Bracket Disassembly And Assembly....3563
Removal And Installation....3563
OPERATOR SEAT (SUSPENSION)....3566
Removal And Installation....3566
Slide Rail Removal And Installation....3566
Seat Belt Removal And Installation....3567
Lower Cushion Removal....3567
Lower Cushion Installation....3568
Back Cushion Removal And Installation....3568
Shock Removal And Installation....3569
3-Point Seat Belt Removal And Installation....3569
BOB-TACH (HAND LEVER)....3572
Description....3572
Removal And Installation....3572
Lever And Wedge Disassembly And Assembly....3574
Pivot Pin Bushing And Seal Removal And Installation....3576
BOB-TACH (POWER)....3578
Description....3578
Removal And Installation....3578
Lever And Wedge Disassembly And Assembly....3581
Pivot Pin Bushing And Seal Removal And Installation....3582
LIFT ARMS....3584
Stabilizer Bar Removal And Installation....3584
Link Removal And Installation....3585
Removal And Installation....3586
REAR GRILLE....3590
Removing....3590
Installing....3590
REAR DOOR (TAILGATE)....3592
Removal And Installation....3592
Striker Removal And Installation....3593
Striker Disassembly And Assembly....3593
Striker Adjusting....3594
Latch Removal And Installation....3594
FUEL TANK....3596
Removal And Installation....3596
Fuel Level Sender Removal And Installation....3598
Fuel Fill Screen Removal And Installation....3598
FLOOR PAN....3600
Removal And Installation....3600
CONTROL PANEL....3602
Description....3602
Removal And Installation....3602
JOYSTICK CONTROL....3604
Description....3604
Joystick Testing....3604
Joystick Removal And Installation....3605
ACCESS PANEL (INSIDE)....3606
Removal And Installation (Left)....3606
Removal And Installation (Right)....3606
WINDOW (REAR)....3608
Removal And Installation....3608
Disassembly And Assembly....3608
WINDOW (TOP)....3610
Removal And Installation....3610
WINDOW (SIDE)....3612
Removal And Installation....3612
CAB DOOR....3614
Description....3614
Removal And Installation....3614
Disassembly And Assembly....3615
Aligning....3616
Adjusting....3617
Checking Operation....3617
ARMREST....3618
Description....3618
Removal And Installation....3619
Disassembly And Assembly....3620
LEFT SIDE LOWER PANEL....3622
Removal And Installation....3622
Disassembly And Assembly....3624
RIGHT SIDE LOWER PANEL....3626
Removal And Installation....3626
Disassembly And Assembly....3627
HEADLINER....3630
Removal And Installation....3630
ELECTRICAL SYSTEM AND ANALYSIS....3632
ELECTRICAL SCHEMATICS....3636
ELECTRICAL SYSTEM INFORMATION....3659
Glossary Of Electrical Symbols....3659
Cab Harness Connectors....3662
Mainframe Harness Connectors....3663
All-wheel Steer Harness Connectors....3664
Engine Harness Connectors....3665
Description....3666
Troubleshooting....3667
Fuse And Relay Location / Identification....3668
Solenoid Testing....3670
BATTERY....3671
Removal And Installation....3671
Servicing....3672
Using A Booster Battery (Jump Starting)....3673
ALTERNATOR....3675
Belt Adjustment....3675
Belt Replacement....3675
Charging System Inspection....3676
Alternator Voltage Testing....3677
Low Voltage Testing....3677
High Voltage Testing....3678
Removal And Installation....3678
Parts Identification....3680
STARTER....3681
Testing....3681
Removal And Installation....3681
Parts Identification....3682
INSTRUMENT PANELS....3683
Left Panel....3683
Display Screen....3685
Right Panel (Standard Key Panel)....3685
Right Panel (Keyless Start Panel)....3686
Right Panel (Deluxe Instrumentation Panel)....3687
Left Switch Panel....3689
Right Switch Panel....3689
Left Side Lower Panel....3690
Right Side Lower Panel....3690
Left Panel Removal And Installation....3691
Right Panel Removal And Installation....3691
Key Switch Disassembly And Assembly....3692
Alarm Disassembly And Assembly....3692
Left Switch Panel Removal And Installation....3693
Right Switch Panel Removal And Installation....3693
LIGHTS....3695
Front Removal And Installation....3695
Rear Removal And Installation....3696
Cab Light Removal And Installation....3696
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)....3697
Description....3697
Connector Identification....3698
Removal And Installation....3704
BOBCAT CONTROLLER (ACS)....3705
Description....3705
Connector And Wire Identification....3706
Removal And Installation....3707
BOBCAT CONTROLLER (DRIVE PLUS)....3709
Description....3709
Connector Identification....3710
Removal And Installation....3712
ENGINE CONTROL UNIT (ECU)....3713
Description....3713
Cleaning....3714
Removal And Installation....3715
WHEEL POSITION SENSORS....3717
Description....3717
Wheel Alignment (Field Adjustment)....3718
Testing....3719
Sensor Removal And Installation....3721
Wheel Alignment (Field Adjustment With Service Analyzer)....3723
Wheel Alignment (Calibration)....3727
DIAGNOSTIC SERVICE CODES....3731
Viewing Service Codes....3731
Service Codes List....3732
DIAGMASTER DIAGNOSTIC TROUBLE CODES (DCT)....3739
Viewing Trouble Codes....3739
BOBCAT INTERLOCK CONTROL SYSTEM (BICS?)....3741
Description....3741
Inspecting The BICS? (Engine STOPPED - Key ON)....3742
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....3742
Inspecting The Seat Bar Sensor (Engine RUNNING)....3742
Inspecting The Traction Lock (Engine RUNNING)....3742
Inspecting The Lift Arm Bypass Control....3742
Inspecting Deactivation Of Lift And Tilt Functions....3742
Troubleshooting....3743
SEAT BAR SENSOR....3745
Description....3745
Troubleshooting....3745
Testing....3746
Removal And Installation....3747
Bobcat Interlock Control System (BICS?) Circuit Test....3750
TRACTION LOCK....3753
Description....3753
Troubleshooting....3754
Inspecting....3755
ELECTRICAL / HYDRAULIC CONTROLS....3757
Identification Chart....3757
Description....3758
Identification Chart ACD Group 0....3759
Identification Chart ACD Group 1....3760
Identification Chart ACD Group 2....3761
Identification Chart ACD Group 3....3762
SERVICE PC (LAPTOP COMPUTER)....3763
Connecting Remote Start Tool....3763
Connecting Remote Start Tool (Service Tool)....3763
Connecting Diagmaster (Service Tool)....3764
Connecting Remote Parked Regeneration Kit....3764
CALIBRATION....3765
Description....3765
Actuator Testing....3765
Lift And Tilt Calibration....3768
Hydrostatic Pump Calibration....3770
STEERING DRIFT COMPENSATION....3775
Description....3775
Operation....3775
CONTROL PANEL SETUP....3777
Right Panel Setup (Deluxe Instrumentation Panel)....3777
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....3781
Password Description....3781
Changing The Owner Password....3781
Changing The User Passwords....3782
Password Lockout Feature....3782
PASSWORD SETUP (KEYLESS START PANEL)....3783
Password Description....3783
Changing The Owner Password....3783
Password Lockout Feature....3783
MAINTENANCE CLOCK....3785
Description....3785
Setup....3786
Reset....3789
BACK-UP ALARM SYSTEM....3791
Description....3791
Inspecting....3791
Troubleshooting....3792
Alarm Removal And Installation....3793
FRONT HORN....3795
Description....3795
Inspecting....3795
Removal And Installation....3795
Troubleshooting....3796
ENGINE SERVICE....3797
ENGINE INFORMATION....3801
Description....3801
Specifications....3802
Sensor Location....3805
Torque Values....3808
Troubleshooting....3809
Engine Removal And Installation....3810
Engine Mount Replacement....3822
Compression - Testing....3824
ENGINE SPEED CONTROL (HAND)....3827
Removal And Installation....3827
ENGINE SPEED CONTROL (FOOT)....3829
Removal And Installation....3829
Disassembly And Assembly....3830
DIESEL PARTICULATE FILTER (DPF) SYSTEM....3833
Description....3833
Removal And Installation....3834
DPF Regeneration....3837
DPF Regeneration Table....3837
Operation (Standard Switch)....3838
Operation (Optional Inhibit Switch Kit)....3839
Operation (Optional Remote Parked Regeneration Kit)....3840
Remote Parked Regeneration (Level 3)....3840
DPF Service Regeneration (Level 4)....3842
DPF Cleaning (Level 5)....3845
AIR CLEANER....3847
Housing Removal And Installation....3847
ENGINE COOLING SYSTEM....3849
Radiator Removal And Installation....3849
Hydraulic Fan Description....3850
Fan Duct Removal And Installation....3851
Hydraulic Fan Motor Assembly Removal And Installation....3851
Hydraulic Fan Motor Removal And Installation....3852
Hydraulic Fan Motor Disassembly And Assembly....3853
Blower Housing Removal And Installation....3855
Water Pump Removal And Installation....3855
Water Pump Disassembly And Assembly....3856
Thermostat Housing Removal And Installation....3856
Thermostat - Testing....3857
LUBRICATION SYSTEM....3859
Oil Pan Removal And Installation....3859
Oil Pump Removal And Installation....3860
Oil Pump Inspection....3860
Oil Filter Cooler Removal And Installation....3862
Engine Oil Pressure - Testing....3863
Crankcase Ventilation Filter Removal And Installation....3864
FUEL SYSTEM....3865
Supply Pump Removal....3865
Supply Pump Installation....3868
Supply Pump Difference Learning....3870
Fuel Rail Assembly Removal And Installation....3872
Supply Pump - Timing....3873
Fuel Injector Removal And Installation....3874
Injector Correction....3878
CYLINDER HEAD....3879
Intake Air Heater - Testing....3879
Intake Air Heater Removal And Installation....3879
Valve Clearance Adjustment....3881
Cylinder Head Removal And Installation....3882
Cylinder Head Disassembly And Assembly....3884
Cylinder Head - Servicing....3884
Cylinder Head Top Clearance....3884
Valve Guide - Inspecting....3885
Reconditioning The Valve And Valve Seat....3887
Valve Spring....3889
Valve Tappets....3890
Rocker Arm And Shaft - Inspecting....3891
Valve Bridge Arm And Shaft - Inspecting....3892
Push Rod Alignment - Inspecting....3892
CRANKSHAFT AND PISTONS....3893
Piston And Connecting Rod Removal And Installation....3893
Piston And Connecting Rod - Servicing....3895
Cylinder Bore - Testing....3899
Connecting Rod Alignment....3900
Crankshaft Gear Removal And Installation....3900
Crankshaft And Bearings Removal....3901
Crankshaft And Bearings Installation....3903
Crankshaft And Bearings - Servicing....3905
CRANKSHAFT POSITION SENSOR....3911
Description....3911
Removal And Installation....3911
Adjusting....3912
CAMSHAFT AND TIMING GEARS....3915
Timing Gearcase Cover Removal And Installation....3915
Timing Gears Backlash - Testing....3916
Idler Gear And Camshaft Removal And Installation....3916
Camshaft - Servicing....3917
Idler Gear And Shaft - Servicing....3919
TURBOCHARGER....3923
Description....3923
Removal And Installation....3924
Testing....3926
EGR Cooler Testing....3927
FLYWHEEL AND HOUSING....3929
Flywheel Removal And Installation....3929
Ring Gear Removal And Installation....3929
Housing Removal And Installation....3930
EXHAUST GAS RECIRCULATION (EGR) SYSTEM....3931
Description....3931
Testing....3932
Removal And Installation....3934
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....3935
AIR CONDITIONING SYSTEM FLOW....3937
Description....3937
Chart....3938
Components....3939
Safety Equipment....3942
REGULAR MAINTENANCE....3943
Filters....3943
Belt Adjustment....3944
Belt Replacement....3944
Condenser....3944
Air Conditioning Lubrication....3944
Air Conditioning Service Chart....3945
Evaporator / Heater Coil....3946
TROUBLESHOOTING....3947
Blower Motor Does Not Operate....3947
Blower Motor Operates Normally, But Air Flow Is Insufficient....3947
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....3947
The Compressor Does Not Operate At All, Or Operates Improperly....3947
Gauge Pressure Related Troubleshooting....3948
Troubleshooting Tree....3950
Temperature / Pressure Chart....3953
Poor A/C Performance....3955
HVAC Repair And Leaks....3956
Electrical System....3957
Engine Coolant Bypassing The Heater Valve....3963
Heater Valve Not Opening Or Closing....3964
SYSTEM CHARGING AND RECLAMATION....3965
Refrigerant Identification....3965
Reclamation And Charging With Recovery / Charging Unit....3966
COMPRESSOR....3969
Removal And Installation....3969
Oil....3971
Oil Check....3972
CONDENSER....3973
Removal And Installation....3973
RECEIVER / DRIER....3975
Receiver / Drier Removal And Installation....3975
Pressure Relief Valve Removal And Installation....3976
Pressure Switch Removal And Installation....3977
Schrader? Valve Removal And Installation....3978
EVAPORATOR / HEATER UNIT....3979
Removal And Installation....3979
THERMOSTAT....3981
Description....3981
Removal And Installation....3982
EXPANSION VALVE....3983
Removal And Installation....3983
EVAPORATOR COIL....3985
Removal And Installation....3985
HEATER COIL....3987
Removal And Installation....3987
BLOWER FAN....3989
Removal And Installation....3989
Disassembly And Assembly....3989
HEATER VALVE....3993
Removal And Installation....3993
SPECIFICATIONS....3995
(A770) LOADER SPECIFICATIONS....3997
Machine Dimensions....3997
Performance....3998
Engine....3998
Drive System....3999
Controls....3999
Hydraulic System....4000
Electrical System....4001
Capacities....4001
Tires....4001
TECHINCAL SERVICE GUIDE SPECIFICATIONS....4003
Engine....4003
Engine Torques....4003
Cooling System....4003
Loader Torques....4004
Hydraulic / Hydrostatic System....4004
Fuel Consumption....4004
TORQUE SPECIFICATION FOR BOLTS....4005
Torque For General SAE Bolts....4005
Torque For General Metric Bolts....4006
HYDRAULIC CONNECTION SPECIFICATIONS....4007
Straight Thread O-ring Fitting....4007
Flare Fitting....4008
Tubelines And Hoses....4008
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....4009
Specifications....4009
CONVERSIONS....4011
Decimal And Millimeter Equivalent Chart....4011
U.S. To Metric Conversion Chart....4011
SERVICE TOOLS REQUIRED....4013
Remote Start Tools....4013
Hydraulic Tools....4014
Mainframe And Drive Tools....4016
Electrical Tools....4016
Engine Tools....4017
HVAC Tools....4019
ALPHABETICAL INDEX....4021
Bobcat All-Wheel Steer Loaders A770 Repair Service Manuals + Operation & Maintenance Manuals
