BOBCAT B700 Backhoe Loader Service Manual SN B44Z11001 PDF DOWNLOAD
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BOBCAT B700 Backhoe Loader Service Manual SN B44Z11001 PDF DOWNLOAD
Language : English
Pages : 797
Downloadable : Yes
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TABLE OF CONTENTS:
BOBCAT B700 Backhoe Loader Service Manual SN B44Z11001 PDF DOWNLOAD
MAINTENANCE SAFETY……………………………………………………………… 3
CONTENTS………………………………………………………………………. 5
GENERAL INFORMATION…………………………………………………………….. 7
MACHINE INFORMATION…………………………………………………………. 9
TECHNICAL PROPERTIES………………………………………………………… 11
Engine…………………………………………………………………. 11
Electrical System……………………………………………………….. 11
Hydraulic System………………………………………………………… 11
Transmission……………………………………………………………. 11
Axle / Brakes…………………………………………………………… 12
Tires………………………………………………………………….. 12
Loader…………………………………………………………………. 12
Backhoe………………………………………………………………… 12
Cab……………………………………………………………………. 12
Steering……………………………………………………………….. 12
Capacities……………………………………………………………… 13
Weights………………………………………………………………… 13
MAIN COMPONENTS…………………………………………………………….. 15
POSITION OF THE MACHINE……………………………………………………… 17
Loader Attachment Position……………………………………………….. 17
Backhoe Attachment Position………………………………………………. 17
SAFETY INSTRUCTION………………………………………………………….. 19
General Safety Information……………………………………………….. 20
Crushing And Burning Prevention…………………………………………… 21
Fire And Explosion Prevention…………………………………………….. 21
Hydraulic Lines And Hoses………………………………………………… 22
STORAGE……………………………………………………………………. 23
Preparing The Machine For Storage…………………………………………. 23
Preparing The Machine For Work After A Long Period Of Storage………………… 23
LUBRICATION AND MAINTENANCE……………………………………………………… 25
LIFTING AND BLOCKING THE BACKHOE LOADER……………………………………….. 27
Procedure………………………………………………………………. 27
APPROVED LIFT ARM SUPPORT DEVICE……………………………………………… 29
Description…………………………………………………………….. 29
TOWING THE BACKHOE LOADER……………………………………………………. 31
Procedure………………………………………………………………. 31
AXLE TOE-IN ADJUSTMENT………………………………………………………. 33
Procedure………………………………………………………………. 33
LUBRICATION………………………………………………………………… 35
General Safety Information……………………………………………….. 35
Fluids, Lubricants And Fuel………………………………………………. 36
Lubricant And Operating Materials Specifications……………………………. 37
Diesel Fuel…………………………………………………………….. 38
Engine Coolant………………………………………………………….. 39
Brake Oil (For S/N B44Z11001 – B44Z11022 Only)……………………………… 42
Transmission Fluid………………………………………………………. 42
Front Axle Oil………………………………………………………….. 42
Rear Axle Oil…………………………………………………………… 42
Lubrication Chart……………………………………………………….. 43
Service Schedule………………………………………………………… 44
Diesel Engine…………………………………………………………… 46
Checking The Engine Oil level…………………………………………….. 46
Cooling System………………………………………………………….. 48
Checking The Coolant Level……………………………………………….. 48
Changing The Coolant…………………………………………………….. 49
Draining Coolant………………………………………………………… 49
Clean The Radiator And Adding Coolant……………………………………… 50
Hydraulic System………………………………………………………… 51
Check Hydraulic Oil Level………………………………………………… 51
To Drain Oil……………………………………………………………. 51
To Replace The Return Filter……………………………………………… 52
To Clean The Suction Strainer…………………………………………….. 52
Replacing The Internal Hydraulic Filter……………………………………. 53
Adding Hydraulic Oil…………………………………………………….. 54
Fuel System…………………………………………………………….. 55
Fuel Specifications……………………………………………………… 55
Biodiesel Blend Fuel…………………………………………………….. 55
To Drain The Contaminant From The Fuel Filter………………………………. 56
To Drain The Contaminant From The Fuel Tank………………………………… 56
To Add Fuel…………………………………………………………….. 57
Transmission System……………………………………………………… 57
Checking Transmission Oil Level…………………………………………… 58
Draining Transmission Oil………………………………………………… 58
To Replace The Filter Elements……………………………………………. 59
Adding Transmission Oil………………………………………………….. 59
Front Axle……………………………………………………………… 59
Draining Axle Oil……………………………………………………….. 60
Adding Oil……………………………………………………………… 60
Reduction Gears…………………………………………………………. 60
To Check Reduction Gear Oil Level…………………………………………. 60
Draining Reduction Gear Oil………………………………………………. 61
Adding Reduction Gear Oil………………………………………………… 61
Rear Axle………………………………………………………………. 61
Checking Rear Axle Oil Level……………………………………………… 61
Cleaning The Rear Axle Breather…………………………………………… 62
Draining Rear Axle Oil…………………………………………………… 62
Adding Rear Axle Oil…………………………………………………….. 62
Brake Fluid (For B700 S/N B44Z11001 – B44Z11022 Only)……………………….. 63
Checking Brake Fluid Reservoir Level (For B700 S/N B44Z11001 – B44Z11022 Only)…. 63
Adding Brake Fluid (For B700 S/N B44Z11023 & Above Only)…………………….. 63
AIR CLEANER SERVICE…………………………………………………………. 65
Engine Air Intake System…………………………………………………. 65
Cleaning The Primary Element……………………………………………… 66
Replacing The Air Filter Elements…………………………………………. 67
Cab Air Filter (If Equipped)……………………………………………… 67
BACKHOE BOOM / SWING LOCK……………………………………………………. 69
Engaging and Disengaging…………………………………………………. 69
ENGINE ALTERNATOR AND FAN BELT……………………………………………….. 71
Replacing Fan And Alternator Belt…………………………………………. 71
Tire MAINTENANCE……………………………………………………………. 73
Type Of Tires…………………………………………………………… 73
To Replace A Wheel………………………………………………………. 73
Wheel Nut Torque Settings………………………………………………… 74
LUBRICATING THE BACKHOE LOADER……………………………………………….. 75
Lubrication Locations……………………………………………………. 75
HYDRAULIC SYSTEM……………………………………………………………….. 79
HYDRAULIC / HYDROSTATIC SCHEMATICS……………………………………………. 81
HYDRAULIC SYSTEM INFORMATION…………………………………………………. 83
Glossary Of Hydraulic / Hydrostatic Symbols………………………………… 83
HYDRAULIC SYSTEM……………………………………………………………. 87
Tests And Hydraulic Pressure Test…………………………………………. 87
Test Ports……………………………………………………………… 88
Hydraulic Tank And Return Filter………………………………………….. 89
Fixed Displacement Tandem Pump……………………………………………. 90
Blocks…………………………………………………………………. 91
Loader Control Valve…………………………………………………….. 92
Steering Priority Valve………………………………………………….. 97
Backhoe Control Valve……………………………………………………. 98
Steering Pressure Test……………………………………………………101
Priority Valve…………………………………………………………..102
RETURN LINE CHECK VALVE………………………………………………………105
Removal And Installation………………………………………………….105
HYDRAULIC CYLINDERS………………………………………………………….107
Basic Type Cylinder Assembly………………………………………………107
Nut Type Cylinder Montage…………………………………………………114
Loader Lift Cylinder……………………………………………………..118
Loader Bucket (Tilt) Cylinder……………………………………………..121
Clampshell Cylinder………………………………………………………124
Backhoe Boom Cylinder…………………………………………………….127
Backhoe Arm Cylinder……………………………………………………..130
Backhoe Bucket Cylinder…………………………………………………..133
Backhoe Extendible Arm Cylinder……………………………………………136
Backhoe Swing Cylinder……………………………………………………139
Backhoe Stabilizer Cylinder……………………………………………….142
HYDRAULIC PUMP………………………………………………………………145
Removal And Installation………………………………………………….145
BACKHOE CONTROL VALVE………………………………………………………..147
Removal And Installation………………………………………………….147
BOOM CYLINDERS………………………………………………………………153
Removal And Installation………………………………………………….153
BUCKET CYLINDERS…………………………………………………………….155
Removal And Installation………………………………………………….155
CLAMP CYLINDERS……………………………………………………………..157
Removal And Installation………………………………………………….157
CLAMSHELL CYLINDERS………………………………………………………….159
Removal And Installation………………………………………………….159
LIFT CYLINDERS………………………………………………………………161
Removal And Installation………………………………………………….161
STABILIZER CYLINDERS…………………………………………………………163
Removal And Installation………………………………………………….163
STICK CYLINDERS……………………………………………………………..165
Removal And Installation………………………………………………….165
SWING CYLINDERS……………………………………………………………..167
Removal And Installation………………………………………………….167
TILT CYLINDERS………………………………………………………………171
Removal And Installation………………………………………………….171
BRAKE PEDAL AND BOOSTER………………………………………………………173
Removal And Installation………………………………………………….173
HYDRAULIC RESERVOIR………………………………………………………….177
Removal And Installation………………………………………………….177
LOADER CONTROL VALVE…………………………………………………………181
Removal And Installation………………………………………………….181
STEERING COLUMN AND UNIT……………………………………………………..185
Removal And Installation………………………………………………….185
ELECTRICAL SYSTEM……………………………………………………………….187
ELECTRICAL SCHEMATICS………………………………………………………..189
ELECTRICAL SYSTEM……………………………………………………………194
Fuses And Relays…………………………………………………………194
Fuses And Relays (For S/N B44Z11023 & Above)………………………………..195
ELECTRICAL SYSTEM……………………………………………………………196
Component Location……………………………………………………….196
Component Location – Carraro………………………………………………202
BATTERY…………………………………………………………………….204
Removal And Installation………………………………………………….204
FUSE……………………………………………………………………….206
Fuse Location……………………………………………………………206
RELAY………………………………………………………………………208
Relay Location…………………………………………………………..208
INSTRUMENT CLUSTERS………………………………………………………….210
Removal And Installation………………………………………………….210
AXLES………………………………………………………………………….214
SAFTEY INSTRUCTIONS………………………………………………………….216
General Safety Recommendations…………………………………………….216
FRONT AXLE………………………………………………………………….218
Description……………………………………………………………..218
Removal And Installation………………………………………………….219
Tightening Torque………………………………………………………..221
Steering Cylinder Group Disassembly………………………………………..223
Steering Cylinder Group Assembly…………………………………………..225
Epicyclic Reduction Gear Group Disassembly………………………………….227
Epicyclic Reduction Gear Group Assembly…………………………………….229
Wheel Hub Group Disassembly……………………………………………….231
Wheel Hub Group Assembly………………………………………………….235
Axle Beam Group Disassembly……………………………………………….239
Axle Beam Group Assembly………………………………………………….241
Differential Support Group Disassembly……………………………………..243
Differential Support Group Assembly………………………………………..246
Differential Group Disassembly…………………………………………….252
Differential Group Assembly……………………………………………….254
Pinion Group Disassembly………………………………………………….255
Pinion Group Assembly…………………………………………………….259
Toe-In / Steering Angle…………………………………………………..264
Toe-In Adjustment………………………………………………………..265
Steering Angle Adjustment…………………………………………………267
Testing After Assembly……………………………………………………268
FRONT SHAFT…………………………………………………………………270
Removal And Installation………………………………………………….270
REAR SHAFT………………………………………………………………….272
Removal And Installation………………………………………………….272
SAFETY INSTRUCTIONS………………………………………………………….274
General Safety Recommendations…………………………………………….274
REAR AXLE…………………………………………………………………..276
Description……………………………………………………………..276
Tightening Torque………………………………………………………..277
Removal And Installation………………………………………………….279
Flange Group Disassembly………………………………………………….282
Flange Group Assembly…………………………………………………….283
Epicyclic Reduction Group Disassembly………………………………………284
Epicyclic Reduction Group Assembly…………………………………………286
Wheel Hub Group Disassembly……………………………………………….288
Wheel Hub Group Assembly………………………………………………….290
Axle Beam Trumpet Group Disassembly………………………………………..292
Axle Beam Trumpet Group Assembly…………………………………………..294
Brake Group……………………………………………………………..296
Brake Group Disassembly…………………………………………………..297
Brake Group Assembly……………………………………………………..299
Brake Control Group Disassembly……………………………………………303
Brake Control Group Assembly………………………………………………308
Differential Support Group Disassembly……………………………………..314
Differential Support Group Assembly………………………………………..317
Differential Group Disassembly…………………………………………….322
Differential Group Assembly……………………………………………….324
Differential Lock………………………………………………………..326
Differential Locking Group Disassembly……………………………………..328
Differential Locking Group Assembly………………………………………..331
Pinion Group Disassembly………………………………………………….334
Pinion Group Assembly…………………………………………………….336
Testing After Assembly……………………………………………………340
SERVICE BRAKE……………………………………………………………….342
Description……………………………………………………………..342
Bleeding The Brake Circuitry (For S/N B44Z11001- B44Z11022 Only)………………343
Bleeding The Brake Circuitry (For S/N B44Z11023 & Above)……………………..344
Brake System Troubleshooting………………………………………………345
TRANSMISSION……………………………………………………………………346
MANUAL USE………………………………………………………………….348
Maintenance……………………………………………………………..348
Repair………………………………………………………………….348
Agreements And Definitions………………………………………………..348
Typographic Agreements……………………………………………………348
Measurements…………………………………………………………….348
General Description………………………………………………………348
Recommendations For Repair Operations………………………………………349
Transmission Installation On The Machine……………………………………350
SAFETY INSTRUCTIONS………………………………………………………….352
General Safety Recommendations…………………………………………….352
TRANSMISSION………………………………………………………………..356
Tightening Torques……………………………………………………….356
Removal And Installation………………………………………………….358
Plugs And Filters………………………………………………………..362
Plugs And Filters Disassembly……………………………………………..363
Plugs And Filters Assembly………………………………………………..365
Converter And Oil Pump Disassembly…………………………………………368
Converter And Oil Pump Assembly……………………………………………370
Pipes And Sensors Disassembly……………………………………………..372
Pipes And Sensors Assembly………………………………………………..373
Hydraulic Control Valve Disassembly………………………………………..374
Hydraulic Control Valve Assembly…………………………………………..381
4WD Solenoid Valve Disassembly…………………………………………….387
4WD Solenoid Valve Assembly……………………………………………….389
Transmission Housing Disassembly…………………………………………..391
Transmission Housing Assembly……………………………………………..400
Shafts A – D Disassembly………………………………………………….410
Shafts A – D Assembly…………………………………………………….420
Shafts B – C Disassembly………………………………………………….430
Shafts B – C Assembly…………………………………………………….440
Shaft E Disassembly………………………………………………………450
Shaft E Assembly…………………………………………………………454
Speed Controls Disassembly………………………………………………..460
Speed Controls Assembly…………………………………………………..463
ENGINE SERVICE………………………………………………………………….466
GENERAL INFORMATION………………………………………………………….470
Introduction…………………………………………………………….470
Engine Views…………………………………………………………….471
Engine Identification…………………………………………………….472
Safety Precautions……………………………………………………….473
Engine Lift Equipment…………………………………………………….475
Viton Seals……………………………………………………………..476
POWERPART Recommended Consumable Products…………………………………..477
SPECIFICATIONS………………………………………………………………480
Basic Engine Data………………………………………………………..480
Data And Dimensions………………………………………………………481
Thread Sealant…………………………………………………………..499
Standard Torque Values……………………………………………………500
Specific Torque Values……………………………………………………501
Compression Test Data…………………………………………………….504
CYLINDER HEAD……………………………………………………………….506
General Description………………………………………………………506
Atomizer Cover…………………………………………………………..506
Rocker Cover…………………………………………………………….507
Rocker Arm………………………………………………………………509
Valve Tip Clearances……………………………………………………..511
Valve Springs……………………………………………………………512
Removal…………………………………………………………………514
Installation…………………………………………………………….516
Valve And Valve Springs…………………………………………………..519
Valve Guides…………………………………………………………….522
Inspection And To Correct…………………………………………………525
PISTON AND CONNECTING ROD ASSEMBLIES…………………………………………..528
General Description………………………………………………………528
Big-End Bearing………………………………………………………….529
Piston And Connecting Rod…………………………………………………531
Piston Rings…………………………………………………………….534
Piston And Connecting Rod Assembly…………………………………………535
Piston And Piston Rings…………………………………………………..537
Connecting Rod…………………………………………………………..538
Partially Finished Small-End Bush………………………………………….539
Piston Cooling Jets………………………………………………………540
CRANKSHAFT ASSEMBLY………………………………………………………….542
General Description………………………………………………………542
Crankshaft Pulley………………………………………………………..543
Rear End Oil Seal Assembly………………………………………………..544
To Remove And To Fit A Wear Sleeve…………………………………………548
Thrust Washers…………………………………………………………..549
Main Bearings……………………………………………………………552
Crankshaft………………………………………………………………554
Balancer Unit……………………………………………………………558
TIMING CASE AND DRIVE ASSEMBLY………………………………………………..562
General Description………………………………………………………562
Timing Cover…………………………………………………………….563
Mechanical Fuel Pump Gear…………………………………………………565
Electronic Fuel Pump Gear…………………………………………………568
Idler Gear And Hub……………………………………………………….570
Heavy Duty Idler Gear…………………………………………………….573
Heavy Duty Idler Gear…………………………………………………….574
Camshaft Gear……………………………………………………………575
Front Oil Seal…………………………………………………………..576
Timing Case……………………………………………………………..579
Crankshaft Gear………………………………………………………….582
Camshaft And Tappets……………………………………………………..583
CYLINDER BLOCK ASSEMBLY………………………………………………………584
General Description………………………………………………………584
Cylinder Block…………………………………………………………..584
Cylinder Bore……………………………………………………………586
ENGINE TIMING……………………………………………………………….588
General Description………………………………………………………588
To Set Number 1 Piston To TDC On The Compression Stroke………………………589
To Check The Timing Of The Bosch VP30 Fuel Injection Pump…………………….590
To Check The Timing Of The Bosch EPVE Fuel Injection Pump…………………….591
To Adjust The Timing Of The Bosch EPVE Fuel Injection Pump……………………592
To Check The Timing Of The Delphi DP210 Fuel Injection Pump…………………..594
To Check The Valve Timing…………………………………………………595
ASPERATION SYSTEM……………………………………………………………596
Exhaust Elbow……………………………………………………………597
Turbocharger Side Mount…………………………………………………..598
Turbocharger Faults………………………………………………………601
Open Engine Breather……………………………………………………..603
Natural Aspirated Engine Breather………………………………………….604
Closed Engine Breather……………………………………………………605
LUBRICATION SYSTEM…………………………………………………………..606
General Description………………………………………………………606
Lubrication System Flow Diagram……………………………………………607
Canister Type Oil Filter………………………………………………….608
Element Type Oil Filter…………………………………………………..609
Filter Head……………………………………………………………..610
Sump……………………………………………………………………611
Dipstick Tube……………………………………………………………613
Oil Strainer And Suction Pipe……………………………………………..614
Lubricating Oil Pump Assembly……………………………………………..615
Relief Valve…………………………………………………………….617
FUEL SYSTEM…………………………………………………………………620
General Description………………………………………………………620
Cold Start Advance Unit (KSB)……………………………………………..622
Typical Fuel System………………………………………………………623
Fuel Filter Assembly……………………………………………………..624
Atomizers……………………………………………………………….625
Fuel Lift Pump and Filter Assembly…………………………………………628
Removing Air From The Fuel System………………………………………….630
Bosch VP30 Fuel Injection Pump…………………………………………….631
Bosch EVPE Fuel Injection Pump…………………………………………….636
Delphi DP210 Fuel Injection Pump…………………………………………..639
COOLING SYSTEM………………………………………………………………644
General Description………………………………………………………644
Coolant Flow Diagram……………………………………………………..645
Thermostat………………………………………………………………646
Coolant Pump…………………………………………………………….649
Fan…………………………………………………………………….653
Fan Drive……………………………………………………………….653
Lubricating Oil Cooler……………………………………………………654
Coolant Bypass Pipe………………………………………………………656
Oil Cooler / Radiator Removal And Installation………………………………657
FLYWHEEL AND HOUSING…………………………………………………………660
General Description………………………………………………………660
Flywheel………………………………………………………………..660
Ring Gear……………………………………………………………….661
Flywheel Housing…………………………………………………………662
ELECTRICAL SYSTEM……………………………………………………………664
General Description………………………………………………………664
Alternator………………………………………………………………664
Starting Aid (Glow Plug)………………………………………………….670
Electrical Components…………………………………………………….672
Engine Control Module (ECM)……………………………………………….674
Voltage Load Protection Module…………………………………………….676
Programming A New ECM…………………………………………………….677
Speed And Timing Sensor…………………………………………………..678
Pressure Sensor………………………………………………………….679
Temperature Sensor……………………………………………………….681
Wiring Harness…………………………………………………………..683
AUXILIARY EQUIPMENT………………………………………………………….690
Power Steering Pump………………………………………………………690
Adaptor For A Hydraulic Pump Or A Steering Pump……………………………..690
Exhauster……………………………………………………………….693
SPECIAL TOOLS……………………………………………………………….694
List Of Special Tools…………………………………………………….694
REAR HAND THROTTLE LEVER……………………………………………………..698
Cable Adjustment Procedure………………………………………………..698
ACCELERATOR PEDAL……………………………………………………………700
Removal And Installation………………………………………………….700
EXHAUST…………………………………………………………………….702
Removal And Installation………………………………………………….702
AIR FILTER………………………………………………………………….704
Housing Removal And Installation…………………………………………..704
ENGINE……………………………………………………………………..706
Removal And Installation………………………………………………….706
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)……………………………………712
HVAC UNIT…………………………………………………………………..714
Removal…………………………………………………………………714
Installation…………………………………………………………….720
MAIN FRAME……………………………………………………………………..734
BACKHOE BOOM / SWING LOCK…………………………………………………….736
Removal And Installation………………………………………………….736
BACKHOE BUCKET TEETH…………………………………………………………738
Removal And Installation………………………………………………….738
LOADER BUCKET TEETH………………………………………………………….740
Removal And Installation………………………………………………….740
BOOM……………………………………………………………………….742
Removal And Installation………………………………………………….742
CAB………………………………………………………………………..744
Removal And Installation………………………………………………….744
CAB (B730)………………………………………………………………….748
Removal And Installation………………………………………………….748
COUNTERWEIGHT……………………………………………………………….760
Removal And Installation………………………………………………….760
ENGINE COVER………………………………………………………………..762
Removal And Installation………………………………………………….762
ENGINE SIDE COVERS…………………………………………………………..764
Removal And Installation………………………………………………….764
FRONT MUDGUARD………………………………………………………………766
Removal And Installation………………………………………………….766
FRONT MUDGUARD (B730 AND B750)………………………………………………..768
Removal And Installation………………………………………………….768
PARKING LEVER……………………………………………………………….770
Removal And Installation………………………………………………….770
FUEL TANK…………………………………………………………………..772
Removal And Installation………………………………………………….772
GRILL FRAME…………………………………………………………………774
Removal And Installation………………………………………………….774
GRILLE……………………………………………………………………..776
Removal And Installation………………………………………………….776
KINGPOST……………………………………………………………………778
Removal And Installation………………………………………………….778
SIDE SHIFT………………………………………………………………….782
Removal And Installation………………………………………………….782
STICK………………………………………………………………………784
Removal And Installation………………………………………………….784
FRONT CONSOLE……………………………………………………………….788
Removal And Installation………………………………………………….788
STABILIZER WEAR PADS…………………………………………………………792
Adjustment………………………………………………………………792
ALPHABETICAL INDEX………………………………………………………………794
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