Bobcat S160 Skid-Steer Loader Service Manual 6987034 (9-09) – PDF DOWNLOAD

Description

Bobcat S160 Skid-Steer Loader Service Manual 6987034 (9-09) – PDF DOWNLOAD

FILE DETAILS:

Bobcat S160 Skid-Steer Loader Service Manual 6987034 (9-09) – PDF DOWNLOAD

Language : English
Pages : 950
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S160 Skid-Steer Loader Service Manual 6987034 (9-09) – PDF DOWNLOAD

S/N 529960001 & Above
S/N 530060001 & Above
S/N AC3260001 & Above
S/N AHWA11001 & Above

FOREWORD:

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

A general inspection of the following items must be made after the loader has had service or repair:

TABLE OF CONTENTS:

Bobcat S160 Skid-Steer Loader Service Manual 6987034 (9-09) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrestor 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
BOBCAT LOADER IDENTIFICATION 17
SAFETY & MAINTENANCE 19
LIFTING AND BLOCKING THE LOADER 23
Procedure 23
LIFT ARM SUPPORT DEVICE 25
Installing 25
Removing 26
OPERATOR CAB 27
Description 27
Raising 28
Lowering 29
Cab Door Sensor 30
Special Applications Kit 30
Special Applications Kit Inspection And Maintenance 30
TRANSPORTING THE LOADER ON A TRAILER 31
Loading And Unloading 31
Fastening 31
TOWING THE LOADER 33
Procedure 33
REMOTE START TOOL KIT -MEL1563 35
Remote Start Tool – MEL1563 35
Service Tool Harness Control – MEL1565 36
Service Tool Harness Communicator – MEL1566 37
Remote Start Procedure 38
REMOTE START TOOL (SERVICE TOOL) kIT – 6689779 41
Description 41
Remote Start Tool (Service Tool) – 6689778 42
Loader Service Tool Harness – 6689747 43
Computer Service Tool Harness – 6689746 44
Remote Start Procedure 45
SERVICE SCHEDULE 49
Chart 49
AIR CLEANER SERVICE 51
Replacing Filter Elements 51
ENGINE COOLING SYSTEM 53
Cleaning 53
Checking Level 54
Removing And Replacing Coolant 55
FUEL SYSTEM 57
Fuel Specifications 57
Biodiesel Blend Fuel 57
Filling The Fuel Tank 58
Fuel Filter 59
Removing Air From The Fuel System 59
ENGINE LUBRICATION SYSTEM 61
Checking And Adding Engine Oil 61
Engine Oil Chart 61
Removing And Replacing Oil And Filter 62
HYDRAULIC / HYDROSTATIC SYSTEM 63
Checking And Adding Fluid 63
Hydraulic / Hydrostatic Fluid Chart 63
Removing And Replacing Hydraulic Fluid 64
Removing And Replacing Hydraulic / Hydrostatic Filter 64
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders) 65
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders) 66
Removing And Replacing Hydraulic Charge Filter 68
Breather Cap 69
FINAL DRIVE TRANSMISSION (CHAINCASE) 71
Checking And Adding Oil 71
Removing And Replacing Oil 71
BOB-TACH (HAND LEVER) 73
Inspection And Maintenance 73
BOB-TACH (POWER) 75
Inspection And Maintenance 75
LUBRICATING THE LOADER 77
Lubrication Locations 77
TIRE MAINTENANCE 79
Wheel Nuts 79
Rotating 79
Mounting 79
SPARK ARRESTOR MUFFLER 81
Cleaning Procedure 81
PIVOT PINS 83
Inspection And Maintenance 83
LOADER STORAGE AND RETURN TO SERVICE 85
Storage 85
Return to Service 85
STOPPING THE ENGINE AND LEAVING THE LOADER 87
Procedure 87
EMERGENCY EXIT 89
Rear Window 89
Front Door 89
HYDRAULIC SYSTEM 91
HYDRAULIC / HYDROSTATIC SCHEMATICS 97
HYDRAULIC SYSTEM INFORMATION 113
Glossary Of Hydraulic / Hydrostatic Symbols 113
Troubleshooting 117
CYLINDER (LIFT) 119
Testing 119
Removal And Installation 120
Parts Identification 121
Disassembly and Assembly 122
CYLINDER (TILT) 125
Testing 125
Removal And Installation 126
Base End Pivot Pin Removal and Installation 127
Rod End Pivot Pin Bushing And Seal Removal And Installation 128
Parts Identification 129
Disassembly And Assembly 130
CYLINDER (BOB-TACH) 133
Testing 133
Removal And Installation 134
Parts Identification 135
Disassembly and Assembly 136
MAIN RELIEF VALVE 139
Description 139
Testing 140
Adjusting 141
Removal and Installation 142
HYDRAULIC CONTROL VALVE (STANDARD) 143
Description 143
Removal And Installation 143
Identification Chart 148
Mount Bracket Removal And Installation 149
Lift Load Check Valve Removal And Installation 149
Load Check Valve Removal And Installation (Tilt & Auxiliary) 150
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 151
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 152
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 152
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 153
Port Relief Valve Removal And Installation 153
Plug Removal And Installation 154
Rubber Boot Removal And Installation 155
End Cap / Spool Lock Block Removal And Installation 156
Lift Spool And Detent Removal And Installation 157
Tilt Spool Removal And Installation 167
Auxiliary Spool Removal And Installation 169
Auxiliary Solenoid Removal And Installation (S/N 529960001 & Above, 530060001 & Above And AC3260001 & Above) 171
Auxiliary Solenoid Removal And Installation (S/N AHWA11001 & Above) 172
Solenoid Removal And Installation 172
Lock Valve Removal And Installation 174
Lift Arm Bypass Orifice Removal And Installation 176
Main Relief Valve Removal And Installation 176
Check Valve Removal And Installation 177
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 179
Description 179
Removal And Installation 179
Actuator Removal And Installation (Out of Loader) 184
Identification Chart 187
Mount Bracket Removal And Installation 188
Lift Load Check Valve Removal And Installation 188
Load Check Valve Removal And Installation (Tilt & Auxiliary) 189
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 190
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 191
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 191
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 192
Port Relief Removal And Installation 192
Plug Removal And Installation 193
End Cap Block Removal And Installation 194
Lift Spool And Detent Removal And Installation 195
Tilt Spool Removal And Installation 200
Auxiliary Spool Removal And Installation 202
Auxiliary Solenoid Removal And Installation (S/N 529960001 & Above, 530060001 & Above And AC3260001 & Above) 204
Auxiliary Solenoid Removal And Installation (S/N AHWA11001 & Above) 205
Solenoid Removal And Installation 205
Lock Valve Removal And Installation 207
Lift Arm Bypass Orifice Removal And Installation 208
Main Relief Valve Removal And Installation 209
Check Valve Removal And Installation 210
LIFT ARM BYPASS CONTROL VALVE 211
Description 211
Testing 211
Removal and Installation 211
Disassembly And Assembly 212
HYDRAULIC PUMP (STANDARD) 213
Description 213
Pump Test at Quick Couplers 213
Direct Pump Test (Standard Section) 214
Direct Pump Test (Charge Section) 216
Removal And Installation 218
Hydraulic Pump Startup 220
Parts Identification 221
Disassembly And Assembly 222
HYDRAULIC PUMP (STANDARD) (HIGH FLOW) 231
Description 231
Pump Test At Quick Couplers 231
Direct Pump Test (Standard Section) 232
Direct Pump Test (Charge Section) 234
Direct Pump Test (High Flow Section) 236
Removal And Installation 238
Hydraulic Pump Startup 240
Parts Identification 241
Disassembly And Assembly 242
HYDRAULIC PUMP (SJC) 255
Description 255
Pump Test At Quick Couplers 255
Direct Pump Test (Standard Section) 256
Direct Pump Test (Charge Section) 258
Removal And Installation 260
Hydraulic Pump Startup 262
Parts Identification 263
Disassembly And Assembly 264
HYDRAULIC PUMP (SJC) (HIGH FLOW) 273
Description 273
Pump Test At Quick Couplers 273
Direct Pump Test (Standard Section) 274
Direct Pump Test (Charge Section) 276
Direct Pump Test (High Flow Section) 278
Removal And Installation 280
Hydraulic Pump Startup 282
Parts Identification 283
Disassembly And Assembly 284
HYDRAULIC / HYDROSTATIC FILTERS 297
Description 297
Housing Removal And Installation 297
Charge Filter Housing Removal And Installation (S/N 529960001 & Above, 530060001 & Above And AC3260001 & Above) 299
HYDRAULIC FLUID RESERVOIR 301
Description 301
Removal And Installation 301
Hydraulic Fluid Screen 304
OIL COOLER 305
Description 305
Removal and Installation 305
BUCKET POSITION VALVE 307
Description 307
Solenoid Removal And Installation 307
Solenoid Testing 308
Removal And Installation 309
Disassembly And Assembly 310
REAR AUXILIARY DIVERTER VALVE 313
Description 313
Solenoid Testing 313
Removal And Installation 314
Disassembly And Assembly 317
BOB-TACH (POWER) BLOCK 323
Description 323
Removal And Installation 323
Disassembly And Assembly 325
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 329
Description 329
Removal and Installation 329
Disassembly And Assembly 329
HIGH FLOW VALVE 331
Description 331
High Flow Relief Valve Testing 331
High Flow Relief Valve Adjustment 332
Solenoid Testing 333
Removal And Installation 334
Disassembly And Assembly 335
HYDROSTATIC SYSTEM 339
HYDROSTATIC SYSTEM INFORMATION 341
Troubleshooting 341
Description 342
HYDROSTATIC MOTOR 343
Description 343
Removal And Installation 343
Parts Identification 346
Disassembly and Assembly 347
HYDROSTATIC MOTOR (TWO-SPEED) 353
Description 353
Removal And Installation (Left Side) 354
Removal And Installation (Right Side) 357
Parts Identification 360
Disassembly 361
Assembly 371
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH MANUAL CONTROLS) 383
Description 383
Shaft Seal Removal And Installation 383
Removal And Installation 385
Parts Identification 387
Disassembly and Assembly 388
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC CONTROLS) 393
Description 393
Shaft Seal Removal And Installation 393
Removal And Installation 395
Parts Identification 397
Disassembly and Assembly 398
CHARGE PRESSURE 403
Description 403
Testing (S/N 529960001 & Above, 530060002 & Above And AC3260001 & Above) 403
Sender Removal And Installation 405
Testing (S/N AHWA11001 & Above) 406
Sender Removal And Installation (S/N AHWA11001 & Above) 407
Adjusting 408
HYDROSTATIC PUMP 411
Description 411
Replenishing / High Pressure Relief Valve Removal And Installation 411
Removal And Installation 412
Hydrostatic Pump Startup 413
Parts Identification (Left Half) 414
Parts Identification (Right Half) 415
Disassembly 416
Assembly 422
HYDROSTATIC PUMP (SJC) 429
Description 429
Hydraulic Controller Removal And Installation 430
Removal And Installation 432
Hydrostatic Pump Startup 434
Parts Identification 435
High Pressure Relief and Bypass Valve 436
Charge Relief Valve 437
Disassembly and Assembly 438
Mechanical Neutral Adjustment 454
Hydraulic Controller Neutral Adjustment 457
DRIVE BELT 461
Description 461
Shield Removal And Installation 461
Adjusting 462
Belt Removal And Installation 463
Tensioner Pulley Removal And Installation 464
Tensioner Pulley Parts Identification 465
Tensioner Pulley Disassembly 466
Tensioner Pulley Assembly 467
TWO-SPEED VALVE 469
Description 469
Valve Removal And Installation 470
Valve Disassembly And Assembly 472
CASE DRAIN FILTER 475
Description 475
Disassembly And Assembly 475
DRIVE SYSTEM 477
BRAKE (SINGLE SPEED) 479
Description 479
Disc Removal And Installation 479
BRAKE (TWO-SPEED) 481
Description 481
Disc Removal And Installation 481
Disc Disassembly and Assembly 482
DRIVE COMPONENTS 483
Description 483
Axle Seal Removal And Installation 484
Axle Sprocket And Bearings Removal And Installation 486
Chain Removal And Installation 491
CHAINCASE 493
Description 493
Front Cover Removal And Installation 493
Center Cover Removal And Installation 494
Rear Cover Removal And Installation 495
MAIN FRAME 497
SEAT BAR 501
Description 501
Removal And Installation 501
Disassembly And Assembly 502
Compression Spring Disassembly And Assembly 504
OPERATOR CAB 505
Gas Cylinder Removal And Installation 505
Gas Cylinder Bracket Disassembly And Assembly 507
Removal And Installation 508
OPERATOR SEAT 511
Removal And Installation 511
Seat Belt Removal And Installation 511
OPERATOR SEAT (SUSPENSION) 513
Removal And Installation 513
Slide Rail Removal And Installation 514
Seat Belt Removal and Installation 514
Lower Cushion Removal And Installation 514
Back Cushion Removal And Installation 516
Shock Removal And Installation 516
3-Point Seat Belt Removal And Installation 517
BOB-TACH (HAND LEVER) 519
Description 519
Removal And Installation 519
Lever And Wedge Disassembly And Assembly 520
Pivot Pin Bushing And Seal Removal And Installation 522
BOB-TACH (POWER) 523
Description 523
Removal And Installation 523
Lever And Wedge Disassembly And Assembly 525
Pivot Pin Bushing And Seal Removal And Installation 526
LIFT ARMS 527
Removal And Installation 527
REAR GRILL 531
Removal And Installation 531
REAR DOOR 533
Removal And Installation 533
Striker Removal and Installation 534
Striker Disassembly and Assembly 534
Striker (Adjusting) 534
Latch Removal and Installation 535
FUEL TANK 537
Removal And Installation 537
Fuel Level Sender Removal And Installation 538
Fuel Fill Screen Removal And Installation 539
CONTROL PEDALS AND LINKAGES 541
Description 541
Pedal Removal And Installation 541
Linkage Removal And Installation 542
Pedal (Adjusting) 544
CONTROL PEDALS (ACS) 545
Description 545
Foot Sensor Removal And Installation 545
Foot Pedal Removal And Installation 546
Foot Pedal Linkage Disassembly And Assembly 547
CONTROL PANEL 549
Description 549
Removal and Installation 550
Shock Removal And Installation 553
Shaft Removal And Installation 553
Shaft Disassembly And Assembly 554
Linkage Removal And Installation 555
Pintle Arm Disassembly and Assembly 559
Linkage Neutral (Adjusting) 561
Linkage Travel (Adjusting) 565
CONTROL PANEL (SJC) 569
Description 569
Removal And Installation 569
CONTROL HANDLE / LEVER 571
Description 571
Lever Removal And Installation 571
Boot Removal And Installation 572
CONTROL HANDLE / LEVER (ACS) 573
Description 573
Handle Sensor Removal And Installation 573
Handle Removal and Installation 576
Handle Disassembly and Assembly 577
Lever Removal and Installation 577
Boot Removal And Installation 579
CONTROL HANDLE / LEVER (SJC) 581
Description 581
Joystick Testing 581
Joystick Removal And Installation 582
Joystick Mount Removal And Installation 583
ACCESS PANEL (INSIDE) 585
Removal And Installation (Left) 585
Removal And Installation (Right) 585
ACCESS PANEL (INSIDE) (SJC) 587
Removal And Installation (Left) 587
Removal And Installation (Right) 588
WINDOW (REAR) 591
Removal 591
Installation (Split Molding) 591
Installation (Continuous Molding) 593
WINDOWS (TOP) 595
Removal And Installation 595
WINDOWS (SIDE) 597
Removal And Installation 597
WINDOWS (CAB DOOR) 599
Removal (Standard Window) 599
Installation (Standard Window) 600
Removal And Installation (Special Applications Window) 602
CAB DOOR 603
Description 603
Removal And Installation 603
Aligning 604
Adjusting 605
Checking Operation 605
ELECTRICAL SYSTEM & ANALYSIS 607
ELECTRICAL SCHEMATICS 611
ELECTRICAL SYSTEM INFORMATION 617
Glossary Of Electrical Symbols 617
Standard Cab Harness Connectors 620
Deluxe Cab Harness Connectors 621
Mainframe Harness Connectors 622
Description 623
Troubleshooting 624
Fuse And Relay Location / Identification 625
Solenoid Testing 626
BATTERY 627
Removal And Installation 627
Servicing 628
Using A Booster Battery (Jump Starting) 629
ALTERNATOR 631
Belt Adjustment 631
Belt Replacement 631
Charging System Inspection 632
Alternator Voltage Testing 633
Low Voltage Testing 633
High Voltage Testing 634
Removal And Installation 635
Parts Identification 636
STARTER 637
Testing 637
Removal And Installation 638
Parts Identification 639
INSTRUMENT PANELS 641
Left Panel 641
Standard Key Panel 643
Deluxe Instrumentation Panel 644
Side Panel 645
Front Panel 645
Front Panel Removal And Installation 646
Removal And Installation (Left And Right) 646
Key Switch Removal And Installation 648
Alarm Removal And Installation 649
LIGHTS 651
Front Removal And Installation 651
Rear Removal And Installation 652
Cab Light Removal And Installation 652
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY) 653
Description 653
Connector Identification 654
Removal and Installation 660
BOBCAT CONTROLLER (ACS) 663
Description 663
Connector Identification 664
Removal and Installation 665
BOBCAT CONTROLLER (SJC) (DRIVE) 667
Description 667
Connector Identification 668
Removal and Installation 670
SPEED SENSORS (SJC) 671
Description 671
Testing 671
Removal and Installation 673
DIAGNOSTIC SERVICE CODES 675
Viewing Service Codes (Standard Key Panel) 675
Viewing Service Codes (Deluxe Instrumentation Panel) 675
Service Codes List 676
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) 681
Description 681
Inspecting The BICS Controller (Engine STOPPED – Key ON) 682
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 682
Inspecting The Seat Bar Sensor (Engine RUNNING) 682
Inspecting The Traction Lock (Engine RUNNING) 682
Inspecting The Lift Arm Bypass Control 682
Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC) 682
Troubleshooting 683
SEAT BAR SENSOR 685
Description 685
Troubleshooting 685
Testing 686
Removal And Installation 687
Bobcat Interlock Control System (BICS) Circuit Test 689
TRACTION LOCK 691
Description 691
Troubleshooting 691
Removal And Installation 692
Inspecting 696
CONTROL SYSTEM (ACS) 697
Description 697
Troubleshooting 698
Handle Sensor Connector Disassembly And Assembly 699
Switch Handle Removal 700
Switch Handle Installation 702
Actuator Connector Disassembly And Assembly 705
Handle Lock Solenoid Removal And Installation 706
Handle Lock Solenoid Disassembly And Assembly 706
Foot Sensor Disassembly And Assembly 707
Foot Lock Solenoid Removal And Installation 708
ELECTRICAL / HYDRAULIC CONTROLS 709
Identification Chart 709
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 711
Identification Chart 711
SERVICE PC (LAPTOP COMPUTER) 715
Connecting Remote Start Tool 715
Connecting Remote Start Tool (Service Tool) 715
CALIBRATION 717
Description 717
Actuator Testing 717
Lift And Tilt Calibration (ACS) 719
Lift And Tilt Calibration (SJC) 721
Hydrostatic Pump Calibration (SJC) 723
STEERING DRIFT COMPENSATION 729
Description 729
Operation 729
FLYWHEEL RPM SENSOR 731
Description 731
Adjusting 731
CONTROL PANEL SETUP 733
Right Panel Setup (Deluxe Instrumentation Panel) 733
Attachment Control Information (Deluxe Instrumentation Panel) 734
PASSWORD SETUP 735
Password Description 735
Changing The Owner Password 735
Changing The User Passwords 736
Password Lockout Feature 736
MAINTENANCE CLOCK 737
Description 737
Setup 738
Reset 741
BACK-UP ALARM SYSTEM 743
Description 743
Inspecting 743
Adjusting Switch Position 744
Troubleshooting (Standard and ACS) 745
Troubleshooting (Joystick) 746
Alarm Removal And Installation 747
Switch Removal And Installation 747
ENGINE SERVICE 749
ENGINE INFORMATION 753
Description 753
Specifications 754
Torque Values 757
Troubleshooting 757
Engine Removal And Installation 759
Engine Mount Replacement 766
Compression – Checking 767
ENGINE SPEED CONTROL 769
Removal And Installation 769
ENGINE SPEED CONTROL (SJC) 771
Removal And Installation 771
Disassembly And Assembly 773
MUFFLER 775
Removal And Installation 775
AIR CLEANER 777
Housing Removal And Installation 777
ENGINE COOLING SYSTEM 779
Radiator Removal And Installation 779
Hydraulic Fan Description (S/N 529960001 & Above, 530060001 & Above And AC3260001 & Above) 782
Hydraulic Fan Disassembly And Assembly (S/N 529960001 & Above, 530060001 & Above And AC3260001 & Above) 782
Blower Housing Removal And Installation (S/N 529960001 & Above, 530060001 & Above And AC3260001 & Above) 783
Fan Removal And Installation (S/N 529960001 & Above, 530060001 & Above And AC3260001 & Above) 785
Hydraulic Fan Motor Removal And Installation (S/N 529960001 & Above, 530060001 & Above And AC3260001 & Above) 785
Hydraulic Fan Description (S/N AHWA11001 & Above) 786
Hydraulic Fan Disassembly And Assembly (S/N AHWA11001 & Above) 786
Blower Housing Removal And Installation (S/N AHWA11001 & Above) 788
Fan Removal And Installation (S/N AHWA11001 & Above) 790
Hydraulic Fan Motor Removal And Installation (S/N AHWA11001 & Above) 790
Water Pump Removal And Installation 791
Water Pump Disassembly And Assembly 791
Thermostat Housing Removal And Installation 792
Thermostat – Checking 793
LUBRICATION SYSTEM 795
Oil Pan Removal And Installation 795
Oil Pump Removal And Installation 795
Oil Pump Inspection 796
Engine Oil Pressure-Testing 797
FUEL SYSTEM 799
Fuel Shutoff Solenoid – Checking 799
Fuel Shutoff Solenoid Removal And Installation 799
Fuel Injection Pump – Checking 800
Fuel Injection Pump Removal And Installation 801
Governor Disassembly And Assembly 805
Fuel Camshaft Removal And Installation 806
Injection Pump – Timing 807
Fuel Injector Removal And Installation 809
Fuel Injector Nozzle Pressure – Checking 810
Nozzle Spray Condition 811
Valve Seat Tightness 811
CYLINDER HEAD 813
Glow Plugs – Testing 813
Glow Plugs Removal And Installation 813
Valve Clearance Adjustment 814
Valve Timing, Checking 815
Cylinder Head Removal And Installation 816
Cylinder Head Disassembly and Assembly 819
Cylinder Head – Servicing 819
Cylinder Head Top Clearance 820
Valve Guide-Checking 820
Reconditioning The Valve And Valve Seat 821
Valve Spring 823
Valve Tappets 824
Rocker Arm And Shaft – Checking 824
Push Rod Alignment – Checking 825
CRANKSHAFT AND PISTONS 827
Piston And Connecting Rod Removal And Installation 827
Piston And Connecting Rod – Servicing 829
Cylinder Bore – Checking 831
Connecting Rod Alignment 831
Crankshaft Gear Removal And Installation 832
Crankshaft And Bearings Removal And Installation 832
Crankshaft And Bearings – Servicing 834
CAMSHAFT AND TIMING GEARS 839
Timing Gearcase Cover Removal And Installation 839
Timing Gears Backlash – Checking 841
Idler Gear And Camshaft Removal And Installation 842
Camshaft – Servicing 843
Idler Gear And Shaft Servicing 844
TURBOCHARGER 845
Description 845
Testing 846
Removal And Installation 846
FLYWHEEL AND HOUSING 849
Flywheel Removal And Installation 849
Ring Gear Removal And Installation 849
Housing Removal And Installation 850
HEATING, VENTILATION, AIR CONDITIONING 853
AIR CONDITIONING SYSTEM FLOW 856
Description 856
Chart 857
Components 858
Safety Equipment 861
REGULAR MAINTENANCE 863
Filters 863
Compressor Drive Belt Adjustment 863
Compressor Drive Belt Replacement 863
Condenser 864
Air Conditioning Lubrication 864
Air Conditioning Service Chart 865
Evaporator / Heater Coil 866
TROUBLESHOOTING 867
Blower Motor Does Not Operate 867
Blower Motor Operates Normally, But Air Flow Is Insufficient 867
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 867
The Compressor Does Not Operate At All, Or Operates Improperly 867
Gauge Pressure Related Troubleshooting 868
Troubleshooting Tree 870
Temperature/Pressure Chart 874
Poor A/C Performance 875
HVAC Repair And Leaks 876
Electrical System 877
Engine Coolant Bypassing The Heater Valve 884
Heater Valve Not Opening Or Closing 885
SYSTEM CHARGING AND RECLAMATION 887
Refrigerant Identification 887
Reclamation And Charging With Recovery / Charging Unit 888
Charging With A Manifold Gauge Set 890
COMPRESSOR 893
Removal And Installation 893
Oil 894
Oil Check 895
Clutch Disassembly And Assembly 897
CONDENSER 901
Removal And Installation 901
RECEIVER / DRIER 903
Receiver / Drier Removal And Installation 903
Pressure Relief Valve Removal And Installation 905
Pressure Switch Removal And Installation 906
Schraeder Valve Removal And Installation 906
EVAPORATOR / HEATER UNIT 907
Removal And Installation 907
THERMOSTAT 909
Removal And Installation 909
EXPANSION VALVE 911
Removal And Installation 911
EVAPORATOR COIL 913
Removal And Installation 913
HEATER COIL 915
Removal And Installation With A/C 915
Removal And Installation Without A/C 917
BLOWER FAN 919
Removal And Installation 919
Disassembly And Assembly 920
Connector Identification 922
HEATER VALVE 923
Removal and Installation 923
Disassembly And Assembly 924
SPECIFICATIONS 925
(S160) LOADER SPECIFICATIONS 927
Machine Dimensions 927
Performance 928
Engine 928
Drive System 928
Controls 929
Hydraulic System 929
Electrical 930
Capacities 930
Tires 930
TORQUE SPECIFICATIONS FOR BOLTS 931
Torque For General SAE Bolts 931
Torque For General Metric Bolts 932
HYDRAULIC CONNECTION SPECIFICATIONS 933
O-ring Face Seal Connection 933
Straight Thread O-ring Fitting 934
Tubelines And Hoses 934
Flare Fitting 935
Port Seal Fitting 936
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 937
Specifications 937
CONVERSIONS 939
Decimal And Millimeter Equivalents 939
U S To Metric Conversion Chart 939
SERVICE MANUAL REVISION 941
Revision No: S160 – 1 941
Revision No: S160 – 2 943
Revision No: S160 – 3 945
Revision No: S160 – 4 947
Revision No: S160 – 5 949

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