Bobcat A770 All-Wheel Steer Loader Service Manual 6990245 – PDF DOWNLOAD

Description

Bobcat A770 All-Wheel Steer Loader Service Manual 6990245 – PDF DOWNLOAD

FILE DETAILS:

Bobcat A770 All-Wheel Steer Loader Service Manual 6990245 – PDF DOWNLOAD

Language : English
Pages : 1093
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat A770 All-Wheel Steer Loader Service Manual 6990245 – PDF DOWNLOAD

S/N ATDW11001 & Above
S/N ATDY11001 & Above

FOREWORD:

This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:

TABLE OF CONTENTS:

Bobcat A770 All-Wheel Steer Loader Service Manual 6990245 – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
LOADER IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE LOADER 23
Procedure 23
LIFT ARM SUPPORT DEVICE 25
Description 25
Installing 25
Removing 27
OPERATOR CAB 29
Description 29
Raising 30
Lowering 31
Cab Door Sensor 32
Special Applications Kit 33
Special Applications Kit Inspection And Maintenance 33
Forestry Door And Window Kit 34
Forestry Door And Window Kit Inspection And Maintenance 34
TRANSPORTING LOADER ON A TRAILER 35
Loading And Unloading 35
Fastening 35
TOWING THE LOADER 37
Procedure 37
REMOTE START TOOL KIT – MEL1563 39
Remote Start Tool – MEL1563 39
Service Tool Harness Communicator – MEL1566 41
Remote Start Procedure 42
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666 45
Description 45
Remote Start Tool (Service Tool) – 7022042 46
Loader Service Tool Harness – 6689747 47
Computer Service Tool Harness – 6689746 48
Remote Start Procedure 49
DIAGMASTER (SERVICE TOOL) KIT – 7024161 53
Diagmaster (Service Tool) 53
DST-i LED Table 54
DST-i Operation Status And Display Specification 54
Diagmaster (Service Tool) Procedure 55
SERVICE SCHEDULE 59
Maintenance Intervals 59
ENGINE AIR CLEANER 61
Replacing Filter Elements 61
ENGINE COOLING SYSTEM 63
Maintenance Platform 63
Cleaning 63
Checking And Adding Coolant 65
Removing And Replacing Coolant 66
FUEL SYSTEM 67
Fuel Specifications 67
Biodiesel Blend Fuel 67
Filling The Fuel Tank 68
Fuel Filter 69
Removing Air From The Fuel System 70
ENGINE LUBRICATION SYSTEM 71
Checking And Adding Engine Oil 71
Engine Oil Chart 71
Removing And Replacing Oil And Filter 72
Removing And Replacing Crankcase Ventilation Filter 74
HYDRAULIC / HYDROSTATIC SYSTEM 75
Checking And Adding Fluid 75
Hydraulic / Hydrostatic Fluid Chart 75
Removing And Replacing Hydraulic Fluid 76
Removing And Replacing Hydraulic / Hydrostatic Filter 78
Removing And Replacing Steering Filter 79
Removing And Replacing Hydraulic Charge Filter 80
Replacing Reservoir Breather Cap 82
FINAL DRIVE TRANSMISSION (CHAINCASE) 83
Checking And Adding Fluid 83
Removing And Replacing Fluid 83
BOB-TACH (HAND LEVER) 85
Inspection And Maintenance 85
BOB-TACH (POWER) 87
Inspection And Maintenance 87
LUBRICATING THE LOADER 89
Lubrication Locations 89
TIRE MAINTENANCE 93
Wheel Nuts 93
Rotating 93
Mounting 94
PIVOT PINS 95
Inspection And Maintenance 95
LOADER STORAGE AND RETURN TO SERVICE 97
Storage 97
Return To Service 97
STOPPING THE ENGINE AND LEAVING THE LOADER 99
Procedure 99
EMERGENCY EXIT 101
Rear Window Identification 101
Rear Window Removal (Latches) 101
Rear Window Removal (Rubber Cord) 101
External Access (Rear Window With Latches) 102
External Access (Rear Window With Rubber Cord) 102
Front Door 103
SEAT BELT 105
Inspection And Maintenance 105
HYDRAULIC SYSTEM 107
HYDRAULIC / HYDROSTATIC SCHEMATICS 113
HYDRAULIC SYSTEM INFORMATION 121
Glossary Of Hydraulic / Hydrostatic Symbols 121
Troubleshooting 125
CYLINDER (LIFT) 127
Testing 127
Removal And Installation 128
Parts Identification 44,5 mm (1 75 in) Rod Diameter 131
Parts Identification 50,8 mm (2 0 in) Rod Diameter 132
Disassembly 133
Assembly 135
CYLINDER (TILT) 139
Testing 139
Removal And Installation 140
Base End Pivot Pin Removal And Installation 141
Parts Identification (Earlier Models) 142
Parts Identification (Later Models) 143
Disassembly 144
Assembly 147
CYLINDER (BOB-TACH) 151
Testing 151
Removal And Installation 152
Parts Identification 153
Disassembly 154
Assembly 155
CYLINDER (STEERING) 159
Testing 159
Removal And Installation (Front) 161
Removal And Installation (Rear) 164
Parts Identification 167
Disassembly 168
Assembly 169
MAIN RELIEF VALVE (EARLIER MODELS) 173
Description 173
Testing 173
Adjusting 175
Removal And Installation 175
MAIN RELIEF VALVE (LATER MODELS) 177
Description 177
Testing 178
Main Relief Valve Adjustment 180
Main Relief Valve Removal And Installation 180
Auxiliary Relief Valve Adjustment 181
Auxiliary Relief Valve Removal And Installation 182
HYDRAULIC CONTROL VALVE (EARLIER MODELS) 183
Description 183
Removal And Installation 183
Actuator Removal And Installation (In Loader) 188
Actuator Removal And Installation (Out Of Loader) 189
Identification Chart 192
Mount Bracket Removal And Installation 193
Lift Load Check Valve Removal And Installation 193
Load Check Valve Removal And Installation (Tilt And Auxiliary) 194
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 195
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 195
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 196
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 196
Port Relief Valve Removal And Installation (Auxiliary) 197
Plug Removal And Installation 198
End Cap Block Removal And Installation 199
Lift Spool Removal And Installation 199
Tilt Spool Removal And Installation 203
Tilt Spool Disassembly And Assembly 204
Auxiliary Spool Removal And Installation 206
Auxiliary Solenoid Removal And Installation 207
Solenoid Removal And Installation 208
Lock Valve Removal And Installation 209
Lift Arm Bypass Orifice Inspection 210
Main Relief Valve Removal And Installation 210
Check Valve Removal And Installation 211
HYDRAULIC CONTROL VALVE (LATER MODELS) 213
Description 213
Removal And Installation 213
Actuator Removal And Installation (In Loader) 218
Actuator Removal And Installation (Out Of Loader) 219
Identification Chart 222
Mount Bracket Removal And Installation 223
Lift Load Check Valve Removal And Installation 223
Load Check Valve Removal And Installation (Tilt And Auxiliary) 224
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 225
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 225
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 226
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 226
Port Relief Valve Removal And Installation 227
Plug Removal And Installation 229
End Cap Block Removal And Installation 230
Lift Spool Removal And Installation 230
Lift Spool Disassembly And Assembly 232
Tilt Spool Removal And Installation 233
Auxiliary Spool Removal And Installation 235
Auxiliary Solenoid Removal And Installation 236
Solenoid Removal And Installation 237
Lock Valve Removal And Installation 238
Lift Arm Bypass Orifice Removal And Installation 240
Main Relief Valve Removal And Installation 240
Auxiliary Relief Valve Removal And Installation 241
Check Valve Removal And Installation 241
LIFT ARM BYPASS CONTROL VALVE 243
Description 243
Testing 243
Removal And Installation 244
Bracket Removal And Installation 245
Disassembly And Assembly 245
HYDRAULIC PUMP 247
Description 247
Pump Test At Quick Couplers 248
Direct Pump Test (Standard Section) 250
Direct Pump Test (Charge Section) 252
Direct Pump Test (Steering Section) 254
Removal And Installation 256
Hydraulic Pump Startup 258
Parts Identification 259
Disassembly And Assembly 260
HYDRAULIC PUMP (HIGH FLOW) 261
Description 261
Pump Test At Quick Couplers 262
Direct Pump Test (Standard Section) 264
Direct Pump Test (Charge Section) 265
Direct Pump Test (High Flow Section) 267
High Flow Relief Valve Adjustment 269
High Flow Relief Valve Removal And Installation 270
Direct Pump Test (Steering Section) 271
Solenoid Removal And Installation 273
Removal And Installation 274
Hydraulic Pump Startup 276
Parts Identification 277
Disassembly And Assembly 278
HYDRAULIC / HYDROSTATIC FILTERS (EARLIER MODELS) 279
Description 279
Housing Removal And Installation 280
HYDRAULIC / HYDROSTATIC FILTERS (LATER MODELS) 283
Description 283
Housing Removal And Installation 283
HYDRAULIC FLUID RESERVOIR (EARLIER MODELS) 285
Description 285
Removal And Installation 285
Hydraulic Fluid Screen 286
HYDRAULIC FLUID RESERVOIR (LATER MODELS) 287
Description 287
Removal And Installation 287
Hydraulic Fluid Screen 288
OIL COOLER (EARLIER MODELS) 289
Description 289
Removal And Installation 289
OIL COOLER (LATER MODELS) 291
Removal And Installation 291
BUCKET POSITION VALVE 293
Description 293
Solenoid Removal And Installation 293
Solenoid Testing 295
Removal And Installation 296
Disassembly And Assembly 298
REAR AUXILIARY DIVERTER VALVE 301
Description 301
Solenoid Testing 301
Removal And Installation 302
Disassembly And Assembly 303
BOB-TACH (POWER) BLOCK (EARLIER MODELS) 309
Description 309
Removal And Installation 309
Disassembly And Assembly 311
BOB-TACH (POWER) BLOCK (LATER MODELS) 321
Description 321
Testing Relief Valve 322
Removal And Installation 324
Disassembly And Assembly 326
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 331
Description 331
Removal And Installation 332
Disassembly And Assembly (FFI/FI) 332
Disassembly And Assembly (FFH/FH) 334
AUTOMATIC RIDE CONTROL 337
Description 337
Removal And Installation 338
Checking The Pressure In The Accumulator 341
Adding Nitrogen To The Accumulator 343
HYDROSTATIC SYSTEM 345
HYDROSTATIC SYSTEM INFORMATION 347
Description 347
Troubleshooting 348
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N ATDW11001 – ATDW11599) 349
Description 349
Removal And Installation 349
Parts Identification 352
Disassembly 353
Assembly 359
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N ATDW11600 AND ATDY11001 & ABOVE) 365
Description 365
Removal And Installation 365
Parts Identification 368
Disassembly 369
Assembly 375
HYDROSTATIC MOTOR CARRIER 381
Description 381
Removal And Installation 382
Parts Identification 384
Disassembly 385
Assembly 387
CHARGE PRESSURE (EARLIER MODELS) 389
Description 389
Testing 390
Sender Removal And Installation 391
Adjusting 392
CHARGE PRESSURE (LATER MODELS) 393
Description 393
Testing 393
Sender Removal And Installation 395
Adjusting 396
HYDROSTATIC PUMP 397
Description 397
Hydraulic Controller Removal And Installation 398
Removal And Installation 400
Hydrostatic Pump Startup 401
Parts Identification 402
High Pressure Relief And Bypass Valve 403
Charge Relief Valve 404
Disassembly 405
Inspection 414
Assembly 417
Mechanical Neutral Adjustment 425
Hydraulic Controller Neutral Adjustment 428
DRIVE BELT 431
Belt Adjustment 431
Stop Adjustment 431
Belt Replacement 431
Tensioner Pulley Removal And Installation 433
Tensioner Pulley Disassembly And Assembly 434
TWO-SPEED / BRAKE VALVE (S/N ATDW11001 – ATDW11599) 435
Description 435
Valve Block Removal And Installation 436
Valve Block Disassembly And Assembly 438
TWO-SPEED / BRAKE VALVE (S/N ATDW11600 AND ATDY11001 & ABOVE) 441
Description 441
Valve Block Removal And Installation 442
Valve Block Disassembly And Assembly 444
DRAIN MANIFOLD 447
Description 447
Drain Manifold Removal And Installation 447
DRIVE SYSTEM 449
BRAKE 451
Description 451
STEERING BLOCK 453
Description 453
Identification 454
Removal And Installation 456
Disassembly And Assembly 457
DRIVE COMPONENTS 465
Description 465
Axle Seal Removal And Installation 466
Axle, Sprocket And Bearings Removal And Installation 468
Chain Removal And Installation 473
CHAINCASE 475
Description 475
Front Cover Removal And Installation 475
Center Cover Removal And Installation 476
Rear Cover Removal And Installation 477
HUB 479
Description 479
Removal 479
Installation 482
Disassembly 486
Assembly 489
MAINFRAME 493
SEAT BAR 497
Description 497
Removal And Installation 497
Disassembly And Assembly 498
Compression Spring Disassembly And Assembly 499
OPERATOR CAB 501
Gas Spring Removal And Installation 501
Gas Spring Bracket Disassembly And Assembly 502
Removal And Installation 502
OPERATOR SEAT (SUSPENSION) 505
Removal And Installation 505
Slide Rail Removal And Installation 505
Seat Belt Removal And Installation 506
Lower Cushion Removal 506
Lower Cushion Installation 507
Back Cushion Removal And Installation 507
Shock Removal And Installation 508
3-Point Seat Belt Removal And Installation 508
BOB-TACH (HAND LEVER) 511
Description 511
Removal And Installation 511
Lever And Wedge Disassembly And Assembly 513
Pivot Pin Bushing And Seal Removal And Installation 515
BOB-TACH (POWER) 517
Description 517
Removal And Installation 517
Lever And Wedge Disassembly And Assembly 520
Pivot Pin Bushing And Seal Removal And Installation 522
LIFT ARMS 523
Stabilizer Bar Removal And Installation 523
Link Removal And Installation 524
Removal And Installation 526
REAR GRILLE 529
Removing 529
Installing 529
Shield Removal And Installation 530
REAR DOOR (TAILGATE) 531
Removal And Installation 531
Striker Removal And Installation 532
Striker Disassembly And Assembly 532
Striker Adjusting 532
Latch Removal And Installation (Earlier Models) 533
Latch Removal And Installation (Later Models) 534
FUEL TANK 535
Removal And Installation 535
Fuel Level Sender Removal And Installation 537
Fuel Fill Screen Removal And Installation 537
FLOOR PAN 539
Removal And Installation 539
CONTROL PANEL 541
Description 541
Removal And Installation 541
JOYSTICK CONTROL 543
Description 543
Joystick Testing 543
Joystick Removal And Installation 544
ACCESS PANEL (INSIDE) 545
Removal And Installation (Left) 545
Removal And Installation (Right) 545
WINDOW (REAR) 547
Rear Window Identification 547
Removal (Rubber Cord) 547
Installation (Rubber Cord) 548
Removal And Installation (Latches) 550
Disassembly And Assembly (Latches) 550
WINDOW (TOP) 551
Removal And Installation 551
WINDOW (SIDE) 553
Removal And Installation 553
CAB DOOR 555
Description 555
Removal And Installation 555
Disassembly And Assembly 556
Aligning 557
Adjusting 558
Checking Operation 558
ARMREST 559
Description 559
Removal And Installation 560
Disassembly And Assembly 561
LEFT SIDE LOWER PANEL 563
Removal And Installation 563
Disassembly And Assembly 565
RIGHT SIDE LOWER PANEL 567
Removal And Installation 567
Disassembly And Assembly 568
HEADLINER 571
Removal And Installation 571
ELECTRICAL SYSTEM 573
ELECTRICAL SCHEMATICS 577
ELECTRICAL SYSTEM INFORMATION 678
Glossary Of Electrical Symbols 678
Cab Harness Connectors (Earlier Models) 681
Cab Harness Connectors (Later Models) 682
Mainframe Harness Connectors 683
All-wheel Steer Harness Connectors 684
Engine Harness Connectors 685
Description 686
Troubleshooting 687
Fuse And Relay Location / Identification 688
Solenoid Testing 691
BATTERY 692
Removal And Installation 692
Battery Maintenance 693
Maintaining Battery Charge Level 693
Battery Service During Machine Storage 693
Battery Testing 694
Battery Charging 694
Using A Booster Battery (Jump Starting) 695
ALTERNATOR 696
Belt Adjustment 696
Belt Replacement 696
Charging System Inspection 697
Alternator Voltage Testing 698
Low Voltage Testing 698
High Voltage Testing 699
Removal And Installation 699
Parts Identification 701
STARTER 702
Testing 702
Removal And Installation 702
Parts Identification 703
INSTRUMENT PANELS 704
Left Panel 704
Display Screen 706
Right Panel (Standard Key Panel) 706
Right Panel (Keyless Start Panel) 707
Right Panel (Deluxe Instrumentation Panel) 708
Left Switch Panel 710
Right Switch Panel 710
Left Side Lower Panel 711
Right Side Lower Panel 711
Left Panel Removal And Installation 712
Right Panel Removal And Installation 712
Key Switch Disassembly And Assembly 713
Alarm Disassembly And Assembly 713
Left Switch Panel Removal And Installation 714
Right Switch Panel Removal And Installation 714
LIGHTS 716
Front Removal And Installation 716
Rear Removal And Installation 717
Cab Light Removal And Installation 717
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) 718
Description 718
Connector Identification 719
Removal And Installation 725
BOBCAT CONTROLLER (ACS) 726
Description 726
Connector And Wire Identification 727
Removal And Installation 728
BOBCAT CONTROLLER (DRIVE PLUS) 730
Description 730
Connector Identification 731
Removal And Installation 733
ENGINE CONTROL UNIT (ECU) 734
Description 734
Cleaning 735
Removal And Installation 736
WHEEL POSITION SENSORS 738
Description 738
Wheel Alignment (Field Adjustment) 739
Testing 740
Sensor Removal And Installation 742
Wheel Alignment (Field Adjustment With Service Analyzer) 744
Wheel Alignment (Calibration) 748
DIAGNOSTIC SERVICE CODES 752
Viewing Service Codes 752
Service Codes List 753
DIAGMASTER DIAGNOSTIC TROUBLE CODES (DCT) 760
Viewing Trouble Codes 760
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 762
Description 762
Inspecting The BICS™ (Engine STOPPED – Key ON) 763
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 763
Inspecting The Seat Bar Sensor (Engine RUNNING) 763
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 763
Inspecting The Lift Arm Bypass Control 763
Inspecting Deactivation Of Lift And Tilt Functions 763
Troubleshooting 764
SEAT BAR SENSOR 766
Description 766
Troubleshooting 766
Testing 767
Removal And Installation 768
Bobcat Interlock Control System (BICS™) Circuit Test 771
TRACTION LOCK 774
Description 774
Troubleshooting 775
Inspecting 776
ELECTRICAL / HYDRAULIC CONTROLS 778
Identification Chart 778
Description 779
Identification Chart ACD Group 0 780
Identification Chart ACD Group 1 781
Identification Chart ACD Group 2 782
Identification Chart ACD Group 3 783
SERVICE PC (LAPTOP COMPUTER) 784
Connecting Remote Start Tool 784
Connecting Remote Start Tool (Service Tool) 784
Connecting Diagmaster (Service Tool) 785
Connecting Remote Parked Regeneration Kit 785
CALIBRATION 786
Description 786
Actuator Testing 786
Lift And Tilt Calibration 789
Hydrostatic Pump Calibration 791
STEERING DRIFT COMPENSATION (OPERATOR MODE) 796
Description 796
Operation 796
STEERING DRIFT COMPENSATION (SERVICE MODE) 798
Description 798
Operation 798
CONTROL PANEL SETUP 800
Right Panel Setup (Deluxe Instrumentation Panel) 800
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 804
Password Description 804
Changing The Owner Password 804
Changing The User Passwords 805
Password Lockout Feature 805
PASSWORD SETUP (KEYLESS START PANEL) 806
Password Description 806
Changing The Owner Password 806
Password Lockout Feature 806
MAINTENANCE CLOCK 808
Description 808
Setup 809
Reset 812
BACK-UP ALARM SYSTEM 814
Description 814
Inspecting 814
Troubleshooting 815
Alarm Removal And Installation 816
FRONT HORN 818
Description 818
Inspecting 818
Removal And Installation 818
Troubleshooting 819
BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS 820
Description 820
Removal And Installation 820
Procedure 821
ENGINE SERVICE 822
ENGINE INFORMATION 826
Description 826
Specifications 827
Sensor Location 830
Torque Values 833
Troubleshooting 834
Engine Removal And Installation 835
Engine Mount Replacement 847
Compression – Testing 849
ENGINE SPEED CONTROL (HAND) 852
Removal And Installation 852
ENGINE SPEED CONTROL (FOOT) 854
Removal And Installation 854
Disassembly And Assembly 855
DIESEL PARTICULATE FILTER (DPF) SYSTEM 858
Description 858
Removal And Installation 859
DPF Regeneration 862
DPF Regeneration Table 862
Operation (Standard Switch) 863
Operation (Optional Inhibit Switch Kit) 864
Operation (Optional Remote Parked Regeneration Kit) 865
Remote Parked Regeneration (Level 3) 865
DPF Service Regeneration (Level 4) 867
DPF Cleaning (Level 5) 870
AIR CLEANER 872
Housing Removal And Installation (Earlier Models) 872
Housing Removal And Installation (Later Models) 872
ENGINE COOLING SYSTEM (EARLIER MODELS) 874
Radiator Removal And Installation 874
Hydraulic Fan Description 875
Lower Fan Duct Removal And Installation 876
Hydraulic Fan Motor Assembly Removal And Installation (Earlier Models) 876
Fan Removal And Installation (Earlier Models) 877
Hydraulic Fan Motor Removal And Installation (Earlier Models) 877
Hydraulic Fan Disassembly And Assembly (Earlier Models) 878
Hydraulic Fan Motor Assembly Removal And Installation (Later Models) 880
Fan Removal And Installation (Later Models) 881
Hydraulic Fan Motor Removal And Installation (Later Models) 882
Hydraulic Fan Disassembly And Assembly (Later Models) 883
Blower Housing Removal And Installation 888
Water Pump Removal And Installation 888
Water Pump Disassembly And Assembly 889
Thermostat Housing Removal And Installation 889
Thermostat – Testing 890
ENGINE COOLING SYSTEM (LATER MODELS) 892
Radiator / Oil Cooler Removal And Installation 892
Hydraulic Fan Description 894
Hydraulic Reversing Fan Description 894
Lower Fan Duct Removal And Installation 894
Hydraulic Fan Motor Assembly Removal And Installation 895
Hydraulic Fan Motor Removal And Installation 897
Hydraulic Fan Motor Disassembly And Assembly 898
Blower Housing Removal And Installation 907
Water Pump Removal And Installation 907
Water Pump Disassembly And Assembly 908
Thermostat Housing Removal And Installation 909
Thermostat – Testing 909
LUBRICATION SYSTEM 910
Oil Pan Removal And Installation 910
Oil Pump Removal And Installation 911
Oil Pump Inspection 911
Oil Filter Cooler Removal And Installation 913
Engine Oil Pressure – Testing 914
Crankcase Ventilation Filter Removal And Installation 915
FUEL SYSTEM 916
Supply Pump Removal 916
Supply Pump Installation 919
Supply Pump Difference Learning 921
Fuel Bypass Valve Removal And Installation 922
Fuel Rail Assembly Removal And Installation 923
Supply Pump – Timing 924
Fuel Injector Removal And Installation 925
Injector Correction 929
CYLINDER HEAD 930
Intake Air Heater – Testing 930
Intake Air Heater Removal And Installation 930
Valve Clearance Adjustment 932
Cylinder Head Removal And Installation 933
Cylinder Head Disassembly And Assembly 935
Cylinder Head – Servicing 935
Cylinder Head Top Clearance 935
Valve Guide – Inspecting 936
Reconditioning The Valve And Valve Seat 938
Valve Spring 940
Valve Tappets 941
Rocker Arm And Shaft – Inspecting 942
Valve Bridge Arm And Shaft – Inspecting 943
Push Rod Alignment – Inspecting 943
CRANKSHAFT AND PISTONS 944
Piston And Connecting Rod Removal And Installation 944
Piston And Connecting Rod – Servicing 946
Cylinder Bore – Measuring 950
Connecting Rod Alignment 951
Crankshaft Gear Removal And Installation 951
Crankshaft And Bearings Removal 952
Crankshaft And Bearings Installation 954
Crankshaft And Bearings – Servicing 956
CRANKSHAFT POSITION SENSOR 962
Description 962
Removal And Installation 962
Adjusting 963
CAMSHAFT AND TIMING GEARS 966
Timing Gearcase Cover Removal And Installation 966
Timing Gears Backlash – Testing 967
Idler Gear And Camshaft Removal And Installation 967
Camshaft – Servicing 968
Idler Gear And Shaft – Servicing 970
TURBOCHARGER 974
Description 974
Removal And Installation 975
Testing 977
EGR Cooler Testing 978
FLYWHEEL AND HOUSING 980
Flywheel Removal And Installation 980
Ring Gear Removal And Installation 980
Housing Removal And Installation 981
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 982
Description 982
Testing 983
Removal And Installation 985
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 986
AIR CONDITIONING SYSTEM FLOW 988
Description 988
Chart 989
Components 990
Safety Equipment 993
REGULAR MAINTENANCE 994
Filters 994
Belt Adjustment 995
Belt Replacement 995
Condenser 995
Air Conditioning Lubrication 995
Air Conditioning Service Chart 996
Evaporator / Heater Coil 997
TROUBLESHOOTING 1000
Blower Motor Does Not Operate 1000
Blower Motor Operates Normally, But Air Flow Is Insufficient 1000
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 1000
The Compressor Does Not Operate At All, Or Operates Improperly 1000
Gauge Pressure Related Troubleshooting 1001
Troubleshooting Tree 1003
Temperature / Pressure Chart 1006
Poor A/C Performance 1008
HVAC Repair And Leaks 1009
Electrical System 1010
Engine Coolant Bypassing The Heater Valve 1016
Heater Valve Not Opening Or Closing 1017
SYSTEM CHARGING AND RECLAMATION 1018
Refrigerant Identification 1018
Reclamation And Charging With Recovery / Charging Unit 1019
COMPRESSOR 1022
Removal And Installation 1022
Oil 1024
Oil Check 1025
CONDENSER (EARLIER MODELS) 1026
Removal And Installation 1026
CONDENSER (LATER MODELS) 1028
Removal And Installation 1028
RECEIVER / DRIER (EARLIER MODELS) 1030
Receiver / Drier Removal And Installation 1030
Pressure Relief Valve Removal And Installation 1031
Pressure Switch Removal And Installation 1032
Schrader® Valve Removal And Installation 1033
RECEIVER / DRIER (LATER MODELS) 1034
Receiver / Drier Removal And Installation 1034
Pressure Switch Removal And Installation 1036
Schrader® Valve Removal And Installation 1037
EVAPORATOR / HEATER UNIT 1038
Removal And Installation 1038
THERMOSTAT 1040
Description 1040
Removal And Installation 1041
EXPANSION VALVE 1042
Removal And Installation 1042
EVAPORATOR COIL 1044
Removal And Installation 1044
HEATER COIL 1046
Removal And Installation 1046
BLOWER FAN 1048
Removal And Installation 1048
Disassembly And Assembly 1048
HEATER VALVE 1052
Removal And Installation 1052
EVAPORATOR / HEATER COVER 1054
Removal 1054
Installation 1054
SPECIFICATIONS 1056
LOADER SPECIFICATIONS 1058
Machine Dimensions 1058
Performance 1059
Engine 1059
Drive System 1060
Controls 1060
Hydraulic System 1061
Electrical System 1062
Capacities 1062
Tires 1062
TECHINCAL SERVICE GUIDE SPECIFICATIONS 1064
Engine 1064
Engine Torques 1064
Cooling System 1064
Loader Torques 1065
Hydraulic / Hydrostatic System 1065
Fuel Consumption 1065
TORQUE SPECIFICATION FOR BOLTS 1066
Torque For General SAE Bolts 1066
Torque For General Metric Bolts 1067
HYDRAULIC CONNECTION SPECIFICATIONS 1068
Straight Thread O-ring Fitting 1068
Flare Fitting 1069
Tubelines And Hoses 1069
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 1070
Specifications 1070
CONVERSIONS 1072
Decimal And Millimeter Equivalent Chart 1072
U S To Metric Conversion Chart 1072
SERVICE TOOLS REQUIRED 1074
Remote Start Tools 1074
Hydraulic Tools 1075
Mainframe And Drive Tools 1078
Electrical Tools 1081
Engine Tools 1082
HVAC Tools 1087
ALPHABETICAL INDEX 1088

IMAGES PREVIEW OF THE MANUAL:

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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