(S/N: A3P611001 & Above – S/N: A3P711001 & Above)
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This workshop repair service manual PDF download for the A770 Bobcat All-Wheel Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
Bobcat Loader A770
S/N: A3P611001 & Above
S/N: A3P711001 & Above
TABLE OF CONTENTS :
SAFETY & MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAINFRAME
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
SPECIFICATIONS
ALPHABETICAL INDEX
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6989480 (1-11)
Total Pages : 788
This A770 Bobcat Loader Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
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MAINTENANCE SAFETY
CONTENTS
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrestor Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATIONS
Loader Serial Number
Engine Serial Number
DELIVERY REPORT
LOADER IDENTIFICATION
SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE LOADER
Procedure
LIFT ARM SUPPORT DEVICE
Installing
Removing
OPERATOR CAB
Description
Raising
Lowering
Cab Door Sensor
Special Applications Kit
Special Applications Kit Inspection And Maintenance
Forestry Door And Window Kit
Forestry Door And Window Kit Inspection And Maintenance
TRANSPORTING LOADER ON A TRAILER
Loading And Unloading
Fastening
TOWING THE LOADER
Procedure
REMOTE START TOOL KIT-MEL1563
Remote Start Tool – MEL1563
Service Tool Harness Communicator – MEL1566
Remote Start Procedure
REMOTE START TOOL (SERVICE TOOL) KIT – 7003031
Description
Remote Start Tool (Service Tool) – 7003030
Loader Service Tool Harness – 6689747
Computer Service Tool Harness – 6689746
Remote Start Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Elements
ENGINE COOLING SYSTEM
Maintenance Platform
Cleaning
Checking Level
Removing And Replacing Coolant
FUEL SYSTEM
Fuel Specifications
Biodiesel Blend Fuel
Filling The Fuel Tank
Fuel Filter
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil Chart
Removing And Replacing Oil And Filter
HYDRAULIC / HYDROSTATIC SYSTEM
Checking And Adding Fluid
Hydraulic / Hydrostatic Fluid Chart
Removing And Replacing Hydraulic Fluid
Removing And Replacing Hydraulic / Hydrostatic Filter
Removing And Replacing Steering Filter
Removing And Replacing Hydraulic Charge Filter
Breather Cap
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
Removing And Replacing Oil
BOB-TACH (HAND LEVER)
Inspection And Maintenance
BOB-TACH (POWER)
Inspection And Maintenance
LUBRICATING THE LOADER
Lubrication Locations
TIRE MAINTENANCE
Wheel Nuts
Rotating
Mounting
SPARK ARRESTER MUFFLER
Cleaning Procedure
PIVOT PINS
Inspection And Maintenance
LOADER STORAGE AND RETURN TO SERVICE
Storage
Return To Service
STOPPING THE ENGINE AND LEAVING THE LOADER
Procedure
EMERGENCY EXIT
External Access
Rear Window
Front Door
SEAT BELT
Inspection And Maintenance
HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting
CYLINDER (LIFT)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (TILT)
Testing
Removal And Installation
Base End Pivot Pin Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (BOB-TACH)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (STEERING)
Testing
Removal And Installation (Front)
Removal And Installation (Rear)
Parts Identification
Disassembly
Assembly
MAIN RELIEF VALVE
Description
Testing
Adjusting
Removal And Installation
HYDRAULIC CONTROL VALVE
Description
Removal And Installation
Actuator Removal And Installation (In Loader)
Actuator Removal And Installation (Out Of Loader)
Identification Chart
Mount Bracket Removal And Installation
Lift Load Check Valve Removal And Installation
Load Check Valve Removal And Installation (Tilt And Auxiliary)
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)
Port Relief Valve Removal And Installation (Auxiliary)
Plug Removal And Installation
End Cap Block Removal And Installation
Lift Spool Removal And Installation
Tilt Spool Removal And Installation
Auxiliary Spool Removal And Installation
Auxiliary Solenoid Removal And Installation
Solenoid Removal And Installation
Lock Valve Removal And Installation
Lift Arm Bypass Orifice Inspection
Main Relief Valve Removal And Installation
Check Valve Removal And Installation
LIFT ARM BYPASS CONTROL VALVE
Description
Testing
Removal And Installation
Bracket Removal And Installation
Disassembly And Assembly
HYDRAULIC PUMP
Description
Pump Test At Quick Couplers
Direct Pump Test (Standard Section)
Direct Pump Test (Charge Section)
Direct Pump Test (Steering Section)
Removal And Installation
Hydraulic Pump Startup
Parts Identification
Disassembly And Assembly
HYDRAULIC PUMP (HIGH FLOW)
Description
Pump Test At Quick Couplers
Direct Pump Test (Standard Section)
Direct Pump Test (Charge Section)
Direct Pump Test (High Flow Section)
High Flow Relief Valve Adjustment
High Flow Relief Valve Removal And Installation
Direct Pump Test (Steering Section)
Solenoid Removal And Installation
Removal And Installation
Hydraulic Pump Startup
Parts Identification
Disassembly And Assembly
HYDRAULIC / HYDROSTATIC FILTERS
Description
Housing Removal And Installation
HYDRAULIC FLUID RESERVOIR
Description
Removal And Installation
Hydraulic Fluid Screen
OIL COOLER
Description
Removal And Installation
BUCKET POSITION VALVE
Description
Solenoid Removal And Installation
Solenoid Testing
Removal And Installation
Disassembly And Assembly
REAR AUXILIARY DIVERTER VALVE
Description
Solenoid Testing
Removal And Installation
Disassembly And Assembly
BOB-TACH (POWER) BLOCK
Description
Removal And Installation
Disassembly And Assembly
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
Description
Removal And Installation
Disassembly And Assembly
HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting
Description
HYDROSTATIC MOTOR (TWO-SPEED)
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
HYDROSTATIC MOTOR CARRIER (SJC)
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
CHARGE PRESSURE
Description
Testing
Sender Removal And Installation
Adjusting
HYDROSTATIC PUMP (SJC)
Description
Hydraulic Controller Removal And Installation
Removal And Installation
Hydrostatic Pump Start Up
Parts Identification
High Pressure Relief And Bypass Valve
Charge Relief Valve
Disassembly
Inspection
Assembly
Mechanical Neutral Adjustment
Hydraulic Controller Neutral Adjustment
DRIVE BELT
Belt Adjustment
Belt Replacement
Stop Adjustment
Tensioner Pulley Removal And Installation
Tensioner Pulley Disassembly And Assembly
TWO-SPEED / BRAKE VALVE
Description
Valve Block Removal And Installation
Valve Block Disassembly And Assembly
DRAIN MANIFOLD
Description
Drain Manifold Removal And Installation
DRIVE SYSTEM
BRAKE
Description
STEERING BLOCK
Description
Identification
Removal And Installation
Disassembly And Assembly
DRIVE COMPONENTS
Description
Axle Seal Removal And Installation
Axle, Sprocket And Bearings Removal And Installation
Chain Removal And Installation
CHAINCASE
Description
Front Cover Removal And Installation
Center Cover Removal And Installation
Rear Cover Removal And Installation
HUB
Description
Removal
Installation
Disassembly
Assembly
MAINFRAME
SEAT BAR
Description
Removal And Installation
Disassembly And Assembly
Compression Spring Disassembly And Assembly
OPERATOR CAB
Gas Spring Removal And Installation
Gas Spring Bracket Disassembly And Assembly
Removal And Installation
OPERATOR SEAT (SUSPENSION)
Removal And Installation
Slide Rail Removal And Installation
Seat Belt Removal And Installation
Lower Cushion Removal
Lower Cushion Installation
Back Cushion Removal And Installation
Shock Removal And Installation
3-Point Seat Belt Removal And Installation
BOB-TACH (HAND LEVER)
Description
Removal And Installation
Lever And Wedge Disassembly And Assembly
Pivot Pin Bushing And Seal Removal And Installation
BOB-TACH (POWER)
Description
Removal And Installation
Lever And Wedge Disassembly And Assembly
Pivot Pin Bushing And Seal Removal And Installation
LIFT ARMS
Stabilizer Bar Removal And Installation
Link Removal And Installation
Removal And Installation
REAR GRILLE
Removing
Installing
REAR DOOR (TAILGATE)
Removal And Installation
Striker Removal And Installation
Striker Adjusting
Latch Removal And Installation
FUEL TANK
Removal And Installation
Fuel Level Sender Removal And Installation
Fuel Fill Screen Removal And Installation
FLOOR PAN
Floor Pan Removal And Installation
CONTROL PANEL
Description
Removal And Installation
JOYSTICK CONTROL
Description
Joystick Testing
Joystick Removal And Installation
ACCESS PANEL (INSIDE)
Removal And Installation (Left)
Removal And Installation (Right)
ACCESS PANEL (INSIDE) (SJC)
Removal And Installation (Left)
Removal And Installation (Right)
WINDOW (REAR)
Removal And Installation
Disassembly And Assembly
WINDOW (TOP)
Removal And Installation
WINDOW (SIDE)
Removal And Installation
CAB DOOR
Description
Removal And Installation
Disassembly And Assembly
Aligning
Adjusting
Checking Operation
ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Cab Harness Connectors
Mainframe Harness Connectors
Description
Troubleshooting
Fuse And Relay Location / Identification
Solenoid Testing
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
ALTERNATOR
Belt Adjustment
Belt Replacement
Charging System Inspection
Alternator Voltage Testing
Low Voltage Testing
High Voltage Testing
Removal And Installation
Parts Identification
STARTER
Testing
Removal And Installation
Parts Identification
INSTRUMENT PANELS
Left Panel
Display Screen
Right Panel (Standard Key Panel)
Right Panel (Keyless Start Panel)
Right Panel (Deluxe Instrumentation Panel)
Left Switch Panel
Right Switch Panel
Left Side Lower Panel
Right Side Lower Panel
Left Panel Removal And Installation
Right Panel Removal And Installation
Key Switch Disassembly And Assembly
Alarm Disassembly And Assembly
Left Switch Panel Removal And Installation
Right Switch Panel Removal And Installation
LIGHTS
Front Removal And Installation
Rear Removal And Installation
Cab Light Removal And Installation
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)
Description
Connector Identification
Removal And Installation
BOBCAT CONTROLLER (ACS)
Description
Connector And Wire Identification
Removal And Installation
BOBCAT CONTROLLER (DRIVE PLUS)
Description
Connector Identification
Removal And Installation
SPEED SENSORS
Description
Testing
Removal And Installation
DIAGNOSTIC SERVICE CODES
Viewing Service Codes
Service Codes List
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Description
Inspecting The BICS™ (Engine STOPPED – Key ON)
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
Inspecting The Seat Bar Sensor (Engine RUNNING)
Inspecting The Traction Lock (Engine RUNNING)
Inspecting The Lift Arm Bypass Control
Inspecting Deactivation Of Lift And Tilt Functions (SJC)
Troubleshooting
SEAT BAR SENSOR
Description
Troubleshooting
Testing
Removal And Installation
Bobcat Interlock Control System (BICS™) Circuit Test
TRACTION LOCK
Description
Troubleshooting
Inspecting
ELECTRICAL / HYDRAULIC CONTROLS (SJC)
Identification Chart
Description
Identification Chart ACD Group 0
Identification Chart ACD Group 1
Identification Chart ACD Group 2
Identification Chart ACD Group 3
SERVICE PC (LAPTOP COMPUTER)
Connecting Remote Start Tool
Connecting Remote Start Tool (Service Tool)
CALIBRATION
Description
Actuator Testing
Lift And Tilt Calibration
Hydrostatic Pump Calibration
STEERING DRIFT COMPENSATION
Description
Operation
FLYWHEEL RPM SENSOR
Description
Removal
Installation
CONTROL PANEL SETUP
Right Panel Setup (Deluxe Instrumentation Panel)
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)
Password Description
Changing The Owner Password
Changing The User Passwords
Password Lockout Feature
PASSWORD SETUP (KEYLESS START PANEL)
Password Description
Changing The Owner Password
Password Lockout Feature
MAINTENANCE CLOCK
Description
Setup
Reset
BACK-UP ALARM SYSTEM
Description
Inspecting
Troubleshooting
Alarm Removal And Installation
FRONT HORN
Description
Inspecting
Front Horn Removal And Installation
Troubleshooting
ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Torque Values
Troubleshooting
Engine Removal And Installation
Engine Mount Replacement
Compression – Checking
ENGINE SPEED CONTROL (HAND)
Removal And Installation
Disassembly And Assembly
Cable Removal And Installation
ENGINE SPEED CONTROL (FOOT)
Removal And Installation
Disassembly And Assembly
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
ENGINE COOLING SYSTEM
Radiator Removal And Installation
Hydraulic Fan Description
Fan Duct Removal And Installation
Hydraulic Fan Motor Assembly Removal And Installation
Hydraulic Fan Motor Removal And Installation
Hydraulic Fan Motor Disassembly And Assembly
Blower Housing Removal And Installation
Water Pump Removal And Installation
Water Pump Disassembly And Assembly
Thermostat Housing Removal And Installation
Thermostat – Checking
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Inspection
Oil Filter Cooler Removal And Installation
Engine Oil Pressure – Testing
FUEL SYSTEM
Fuel Shutoff Solenoid – Checking
Fuel Shutoff Solenoid Removal And Installation
Fuel Injection Pump Assembly Removal
Fuel Injection Pump Assembly Installation
Governor Housing Disassembly And Assembly
Governor Disassembly And Assembly
Fuel Camshaft Removal And Installation
Fuel Injection Pump Removal
Fuel Injection Pump Installation
Injection Pump – Timing
Fuel Injector Removal And Installation
Fuel Injector Nozzle Pressure – Checking
Nozzle Spraying Condition
Valve Seat Tightness
CYLINDER HEAD
Intake Air Heater – Testing
Intake Air Heater Removal And Installation
Valve Clearance Adjustment
Valve Timing – Checking
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head – Servicing
Cylinder Head Top Clearance
Valve Guide – Checking
Reconditioning The Valve And Valve Seat
Valve Spring
Valve Tappets
Rocker Arm And Shaft – Checking
Push Rod Alignment – Checking
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod – Servicing
Cylinder Bore – Checking
Connecting Rod Alignment
Crankshaft Gear Removal And Installation
Crankshaft And Bearings Removal
Crankshaft And Bearings Installation
Crankshaft And Bearings – Servicing
CAMSHAFT AND TIMING GEArS
Timing Gearcase Cover Removal And Installation
Timing Gears Backlash – Checking
Idler Gear And Camshaft Removal And Installation
Camshaft – Servicing
Idler Gear And Shaft – Servicing
TURBOCHARGER
Description
Testing
Removal And Installation
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Housing Removal And Installation
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Description
Testing
Removal And Installation
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW
Description
Chart
Components
Safety Equipment
REGULAR MAINTENANCE
Filters
Belt Adjustment
Belt Replacement
Condenser
Air Conditioning Lubrication
Air Conditioning Service Chart
Evaporator / Heater Coil
TROUBLESHOOTING
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
The Compressor Does Not Operate At All, Or Operates Improperly
Gauge Pressure Related Troubleshooting
Troubleshooting Tree
Temperature / Pressure Chart
Poor A/C Performance
HVAC Repair And Leaks
Electrical System
Engine Coolant Bypassing The Heater Valve
Heater Valve Not Opening Or Closing
SYSTEM CHARGING AND RECLAMATION
Refrigerant Identification
Reclamation And Charging With Recovery / Charging Unit
COMPRESSOR
Removal And Installation
Oil
Oil Check
CONDENSER
Removal And Installation
RECEIVER / DRIER
Receiver / Drier Removal And Installation
Pressure Relief Valve Removal And Installation
Pressure Switch Removal And Installation
Schrader® Valve Removal And Installation
EVAPORATOR / HEATER UNIT
Removal And Installation
THERMOSTAT
Description
Removal And Installation
EXPANSION VALVE
Removal And Installation
EVAPORATOR COIL
Removal And Installation
HEATER COIL
Removal And Installation
BLOWER FAN
Removal And Installation
Disassembly And Assembly
HEATER VALVE
Removal And Installation
SPECIFICATIONS
(A770) LOADER SPECIFICATIONS
Machine Dimensions
Performance
Engine
Drive System
Controls
Hydraulic System
Electrical System
Capacities
Tires
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
Straight Thread O-ring Fitting
Flare Fitting
Tubelines And Hoses
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalent Chart
U.S. To Metric Conversion Chart
ALPHABETICAL INDEX
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Bobcat A770 All-Wheel Skid-Steer Loader Repair Service Manual – 6989480.pdf
Source : Sitelux.com
