Bobcat S160 Skid-Steer Loader Service Manual 6987048 (01-15) – PDF DOWNLOAD

Description

Bobcat S160 Skid-Steer Loader Service Manual 6987048 (01-15) – PDF DOWNLOAD

FILE DETAILS:

Bobcat S160 Skid-Steer Loader Service Manual 6987048 (01-15) – PDF DOWNLOAD

Language : English
Pages : 1000
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S160 Skid-Steer Loader Service Manual 6987048 (01-15) – PDF DOWNLOAD

S/N A3L311001 & Above
S/N A3L411001 & Above
S/N AEYN11001 & 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 6987048 (01-15) – 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
Installing 25
Removing 26
OPERATOR CAB 27
Description 27
Raising 28
Lowering 29
Cab Door Sensor 30
Special Applications Kit 31
Special Applications Kit Inspection And Maintenance 31
TRANSPORTING THE LOADER ON A TRAILER 33
Loading And Unloading 33
Fastening 33
TOWING THE LOADER 35
Procedure 35
REMOTE START TOOL KIT – MEL1563 37
Remote Start Tool – MEL1563 37
Service Tool Harness Communicator – MEL1566 39
Remote Start Procedure 40
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666 43
Description 43
Remote Start Tool (Service Tool) – 7022042 44
Loader Service Tool Harness – 6689747 45
Computer Service Tool Harness – 6689746 46
Remote Start Procedure 47
SERVICE SCHEDULE 51
Chart 51
AIR CLEANER SERVICE 53
Replacing Filter Elements 53
ENGINE COOLING SYSTEM 55
Cleaning 55
Checking Level 56
Removing And Replacing Coolant 57
FUEL SYSTEM 59
Fuel Specifications 59
Biodiesel Blend Fuel 59
Filling The Fuel Tank 60
Fuel Filter 61
Removing Air From The Fuel System 61
ENGINE LUBRICATION SYSTEM 63
Checking And Adding Engine Oil 63
Engine Oil Chart 63
Removing And Replacing Oil And Filter 64
HYDRAULIC / HYDROSTATIC SYSTEM 65
Checking And Adding Fluid 65
Hydraulic / Hydrostatic Fluid Chart 65
Removing And Replacing Hydraulic Fluid 66
Removing And Replacing Hydraulic / Hydrostatic Filter 67
Removing And Replacing Hydraulic Case Drain Filters (Single Speed Loaders) 68
Removing And Replacing Hydraulic Case Drain Filters (Two-Speed Loaders) 69
Removing And Replacing Hydraulic Charge Filter 71
Breather Cap 72
FINAL DRIVE TRANSMISSION (CHAINCASE) 73
Checking And Adding Oil 73
Removing And Replacing Oil 73
BOB-TACH® (HAND LEVER) 75
Inspection And Maintenance 75
BOB-TACH® (POWER) 77
Inspection And Maintenance 77
LUBRICATING THE LOADER 79
Lubrication Locations 79
TIRE MAINTENANCE 81
Wheel Nuts 81
Rotating 81
Mounting 81
SPARK ARRESTER MUFFLER 83
Cleaning Procedure 83
PIVOT PINS 85
Inspection And Maintenance 85
LOADER STORAGE AND RETURN TO SERVICE 87
Storage 87
Return To Service 87
STOPPING THE ENGINE AND LEAVING THE LOADER 89
Procedure 89
EMERGENCY EXIT 91
Rear Window 91
Front Door 91
SEAT BELT 93
Inspection And Maintenance 93
HYDRAULIC SYSTEM 95
HYDRAULIC/HYDROSTATIC SCHEMATICS 101
HYDRAULIC SYSTEM INFORMATION 117
Glossary Of Hydraulic / Hydrostatic Symbols 117
Troubleshooting 121
CYLINDER (LIFT) 123
Testing 123
Removal And Installation 124
Parts Identification 125
Disassembly And Assembly 126
CYLINDER (TILT) 129
Testing 129
Removal And Installation 130
Base End Pivot Pin Removal And Installation 131
Rod End Pivot Pin Bushing And Seal Removal And Installation 132
Parts Identification 133
Disassembly And Assembly 134
CYLINDER (BOB-TACH®) 137
Testing 137
Removal And Installation 138
Parts Identification 139
Disassembly And Assembly 140
MAIN RELIEF VALVE 143
Description 143
Testing 144
Adjusting 145
Removal And Installation 146
HYDRAULIC CONTROL VALVE (STANDARD) 147
Description 147
Removal And Installation 148
Identification Chart 153
Mount Bracket Removal And Installation 154
Lift Load Check Valve Removal And Installation 154
Load Check Valve Removal And Installation (Tilt And Auxiliary) 155
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 156
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 157
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 157
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 158
Port Relief Valve Removal And Installation 158
Plug Removal And Installation 159
Rubber Boot Removal And Installation 160
End Cap / Spool Lock Block Removal And Installation 161
Lift Spool And Detent Removal And Installation 162
Tilt Spool Removal And Installation 172
Auxiliary Spool Removal And Installation 174
Auxiliary Solenoid Removal And Installation (S/N A3L334999 & Below And A3L434999 & Below) 176
Auxiliary Solenoid Removal And Installation (S/N A3L335001 & Above And A3L435001 & Above) 177
Solenoid Removal And Installation 178
Lock Valve Removal And Installation 179
Lift Arm Bypass Orifice Removal And Installation 181
Main Relief Valve Removal And Installation 181
Check Valve Removal And Installation 182
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 183
Description 183
Removal And Installation 184
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) 196
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 196
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 197
Port Relief Valve Removal And Installation 197
Plug Removal And Installation 198
End Cap Block Removal And Installation 199
Lift Spool And Detent Removal And Installation 200
Tilt Spool Removal And Installation 205
Auxiliary Spool Removal And Installation 207
Auxiliary Solenoid Removal And Installation (S/N A3L334999 & Below And A3L434999 & Below) 209
Auxiliary Solenoid Removal And Installation (S/N A3L335001 & Above And A3L435001 & Above) 210
Solenoid Removal And Installation 211
Lock Valve Removal And Installation 212
Lift Arm Bypass Orifice Removal And Installation 214
Main Relief Valve Removal And Installation 214
Check Valve Removal And Installation 215
LIFT ARM BYPASS CONTROL VALVE 217
Description 217
Testing 217
Removal And Installation 217
Disassembly And Assembly 218
HYDRAULIC PUMP (STANDARD) 219
Description 219
Pump Test At Quick Couplers 219
Direct Pump Test (Standard Section) 220
Direct Pump Test (Charge Section) 222
Removal And Installation 224
Hydraulic Pump Startup 226
Parts Identification 227
Disassembly And Assembly 228
HYDRAULIC PUMP (STANDARD) (HIGH FLOW) 237
Description 237
Pump Test At Quick Couplers 237
Direct Pump Test (Standard Section) 238
Direct Pump Test (Charge Section) 240
Direct Pump Test (High Flow Section) 242
Removal And Installation 244
Hydraulic Pump Startup 246
Parts Identification 247
Disassembly And Assembly 248
HYDRAULIC PUMP (SJC) 261
Description 261
Pump Test At Quick Couplers 261
Direct Pump Test (Standard Section) 262
Direct Pump Test (Charge Section) 264
Removal And Installation 266
Hydraulic Pump Startup 268
Parts Identification 269
Disassembly And Assembly 270
HYDRAULIC PUMP (SJC) (HIGH FLOW) 279
Description 279
Pump Test At Quick Couplers 279
Direct Pump Test (Standard Section) 280
Direct Pump Test (Charge Section) 282
Direct Pump Test (High Flow Section) 284
Removal And Installation 286
Hydraulic Pump Startup 288
Parts Identification 289
Disassembly And Assembly 290
HYDRAULIC / HYDROSTATIC FILTERS 303
Description 303
Housing Removal And Installation 304
Charge Filter Housing Removal And Installation 305
HYDRAULIC FLUID RESERVOIR 307
Description 307
Removal And Installation 307
Hydraulic Fluid Screen 310
OIL COOLER 311
Description 311
Removal And Installation 312
BUCKET POSITION VALVE 313
Description 313
Solenoid Removal And Installation 314
Solenoid Testing 315
Removal And Installation 316
Disassembly And Assembly 318
REAR AUXILIARY DIVERTER VALVE 321
Description 321
Solenoid Testing 321
Removal And Installation 322
Disassembly And Assembly 325
BOB-TACH® (POWER) BLOCK 331
Description 331
Removal And Installation 331
Disassembly And Assembly 333
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 337
Description 337
Removal And Installation 337
Disassembly And Assembly 337
HIGH FLOW VALVE 339
Description 339
High Flow Relief Valve Testing 339
High Flow Relief Valve Adjustment 341
Solenoid Testing 341
Removal And Installation 342
Disassembly And Assembly 344
HYDROSTATIC SYSTEM 347
HYDROSTATIC SYSTEM INFORMATION 349
Troubleshooting 349
Description 350
HYDROSTATIC DRIVE MOTOR 351
Description 351
Removal And Installation 352
Parts Identification 354
Disassembly And Assembly 355
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 361
Description 361
Removal And Installation (Left Side) 362
Removal And Installation (Right Side) 365
Parts Identification 368
Disassembly 369
Assembly 379
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH MANUAL CONTROLS) 391
Description 391
Shaft Seal Removal And Installation 392
Removal And Installation 394
Parts Identification 396
Disassembly And Assembly 397
HYDROSTATIC MOTOR CARRIER (SINGLE AND TWO-SPEED WITH SJC CONTROLS) 403
Description 403
Shaft Seal Removal And Installation 404
Removal And Installation 406
Parts Identification 408
Disassembly And Assembly 409
CHARGE PRESSURE 415
Description 415
Testing (S/N A3L329999 & Below And A3L429999 & Below) 416
Sender Removal And Installation (S/N A3L329999 & Below And A3L429999 & Below) 417
Testing (S/N A3L330001 & Above And A3L430001 & Above) 418
Sender Removal And Installation (S/N A3L330001 & Above And A3L430001 & Above) 419
Adjusting 420
HYDROSTATIC PUMP 423
Description 423
Replenishing / High Pressure Relief Valve Removal And Installation 423
Removal And Installation 424
Hydrostatic Pump Startup 425
Parts Identification (Left Half) 426
Parts Identification (Right Half) 427
Disassembly 428
Assembly 434
HYDROSTATIC PUMP (SJC) 441
Description 441
Hydraulic Controller Removal And Installation 442
Removal And Installation 444
Hydrostatic Pump Startup 446
Parts Identification 447
High Pressure Relief And Bypass Valve 448
Charge Relief Valve 449
Disassembly And Assembly 450
Mechanical Neutral Adjustment 466
Hydraulic Controller Neutral Adjustment 469
DRIVE BELT 473
Description 473
Shield Removal And Installation 473
Adjusting 474
Belt Removal And Installation 475
Tensioner Pulley Removal And Installation 476
Tensioner Pulley Parts Identification 477
Tensioner Pulley Disassembly 478
Tensioner Pulley Assembly 479
TWO-SPEED VALVE 481
Description 481
Valve Removal And Installation 482
Valve Disassembly And Assembly 484
CASE DRAIN FILTER 487
Description 487
Disassembly And Assembly 487
DRIVE SYSTEM 489
BRAKE (SINGLE SPEED) 491
Description 491
Disc Removal And Installation 491
BRAKE (TWO-SPEED) 493
Description 493
Disc Removal And Installation 493
Disc Disassembly And Assembly 494
DRIVE COMPONENTS 495
Description 495
Axle Seal Removal And Installation 496
Axle Sprocket And Bearings Removal And Installation 498
Chain Removal And Installation 503
CHAINCASE 505
Description 505
Front Cover Removal And Installation 505
Center Cover Removal And Installation 506
Rear Cover Removal And Installation 507
MAINFRAME 509
SEAT BAR 513
Description 513
Removal And Installation 513
Disassembly And Assembly 514
Compression Spring Disassembly And Assembly 515
OPERATOR CAB 517
Gas Cylinder Removal And Installation 517
Gas Cylinder Bracket Disassembly And Assembly 519
Removal And Installation 520
OPERATOR SEAT 523
Removal And Installation 523
Seat Belt Removal And Installation 523
OPERATOR SEAT (SUSPENSION) 525
Removal And Installation 525
Slide Rail Removal And Installation 526
Seat Belt Removal And Installation 526
Lower Cushion Removal And Installation 526
Back Cushion Removal And Installation 528
Shock Removal And Installation 528
3-Point Seat Belt Removal And Installation 529
BOB-TACH® (HAND LEVER) 531
Description 531
Removal And Installation 531
Lever And Wedge Disassembly And Assembly 532
Pivot Pin Bushing And Seal Removal And Installation 534
BOB-TACH® (POWER) 535
Description 535
Removal And Installation 536
Lever And Wedge Disassembly And Assembly 538
Pivot Pin Bushing And Seal Removal And Installation 540
LIFT ARMS 541
Removal And Installation 541
REAR GRILLE 545
Removal And Installation 545
REAR DOOR (TAILGATE) 547
Removal And Installation 547
Striker Removal And Installation 548
Striker Disassembly And Assembly 548
Striker (Adjusting) 549
Latch Removal And Installation 550
FUEL TANK 551
Removal And Installation 551
Fuel Level Sender Removal And Installation 552
Fuel Fill Screen Removal And Installation 553
CONTROL PEDALS AND LINKAGES 555
Description 555
Pedal Removal And Installation 555
Linkage Removal And Installation 556
Pedal (Adjusting) 558
CONTROL PEDALS (ACS) 559
Description 559
Foot Sensor Removal And Installation 559
Foot Pedal Removal And Installation 560
Foot Pedal Linkage Disassembly And Assembly 561
CONTROL PANEL 563
Description 563
Removal And Installation 564
Shock Removal And Installation 567
Shaft Removal And Installation 567
Shaft Disassembly And Assembly 568
Linkage Removal And Installation 569
Pintle Arm Disassembly And Assembly 573
Linkage Neutral (Adjusting) 575
Linkage Travel (Adjusting) 579
CONTROL PANEL (SJC) 583
Description 583
Removal And Installation 583
CONTROL HANDLE / LEVER 585
Description 585
Lever Removal And Installation 585
Boot Removal And Installation 585
CONTROL HANDLE / LEVER (ACS) 587
Description 587
Handle Sensor Removal And Installation 587
Handle Removal And Installation 590
Handle Disassembly And Assembly 591
Lever Removal And Installation 592
Boot Removal And Installation 593
CONTROL HANDLE / LEVER (SJC) 595
Description 595
Joystick Testing 595
Joystick Removal And Installation 597
Joystick Mount Removal And Installation 598
ACCESS PANEL (INSIDE) 599
Removal And Installation (Left) 599
Removal And Installation (Right) 599
ACCESS PANEL (INSIDE) (SJC) 601
Removal And Installation (Left) 601
Removal And Installation (Right) 602
WINDOW (REAR) 605
Removal 605
Installation (Split Molding) 605
Installation (Continuous Molding) 607
WINDOW (TOP) 609
Removal And Installation 609
WINDOW (SIDE) 611
Removal And Installation 611
WINDOW (CAB DOOR) 613
Removal (Standard Window) 613
Installation (Standard Window) 614
Removal And Installation (Special Applications Window) 616
CAB DOOR 617
Description 617
Removal And Installation 617
Aligning 618
Adjusting 619
Checking Operation 619
ELECTRICAL SYSTEM AND ANALYSIS 621
ELECTRICAL SCHEMATICS 625
ELECTRICAL SYSTEM INFORMATION 631
Glossary Of Electrical Symbols 631
Standard Cab Harness Connectors 634
Deluxe Cab Harness Connectors 635
Mainframe Harness Connectors 636
Description 637
Troubleshooting 638
Fuse And Relay Location / Identification 639
Solenoid Testing 640
BATTERY 641
Removal And Installation 641
Servicing 642
Using A Booster Battery (Jump Starting) 643
ALTERNATOR 645
Belt Adjustment 645
Belt Replacement 645
Charging System Inspection 646
Alternator Voltage Testing 647
Low Voltage Testing 647
High Voltage Testing 648
Removal And Installation 649
Parts Identification 650
STARTER 651
Testing 651
Removal And Installation 652
Parts Identification 653
INSTRUMENT PANELS 655
Left Panel 655
Standard Key Panel 657
Keyless Start Panel 657
Deluxe Instrumentation Panel 658
Side Panel 659
Front Panel 659
Front Panel Removal And Installation 660
Removal And Installation (Left And Right) 660
Key Switch Removal And Installation 663
Alarm Removal And Installation 663
LIGHTS 665
Front Removal And Installation 665
Rear Removal And Installation 666
Cab Light Removal And Installation 666
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY) 667
Description 667
Connector Identification 668
Removal And Installation 674
BOBCAT CONTROLLER (ACS) 677
Description 677
Connector And Wire Identification 678
Removal And Installation 679
BOBCAT CONTROLLER (SJC) (DRIVE) 681
Description 681
Connector Identification 682
Removal And Installation 684
SPEED SENSORS (SJC) 685
Description 685
Testing 685
Removal And Installation 687
DIAGNOSTIC SERVICE CODES 689
Viewing Service Codes 689
Service Codes List 690
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 695
Description 695
Inspecting The BICS™ (Engine STOPPED – Key ON) 696
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 696
Inspecting The Seat Bar Sensor (Engine RUNNING) 696
Inspecting The Traction Lock (Engine RUNNING) 696
Inspecting The Lift Arm Bypass Control 696
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) 696
Troubleshooting 697
SEAT BAR SENSOR 699
Description 699
Troubleshooting 699
Testing 700
Removal And Installation 701
Bobcat Interlock Control System (BICS™) Circuit Test 704
TRACTION LOCK 705
Description 705
Troubleshooting 705
Removal And Installation 706
Inspecting 710
CONTROL SYSTEM (ACS) 711
Description 711
Troubleshooting 712
Handle Sensor Connector Disassembly And Assembly 713
Switch Handle Removal 714
Switch Handle Installation 716
Actuator Connector Disassembly And Assembly 719
Handle Lock Solenoid Removal And Installation 720
Handle Lock Solenoid Disassembly And Assembly 720
Foot Sensor Disassembly And Assembly 721
Foot Lock Solenoid Removal And Installation 722
ELECTRICAL / HYDRAULIC CONTROLS 723
Identification Chart 723
Description 724
Identification Chart ACD Group 0 725
Identification Chart ACD Group 1 726
Identification Chart ACD Group 2 727
Identification Chart ACD Group 3 728
ELECTRICAL / HYDRAULIC CONTROLS (ACS) 729
Identification Chart 729
Description 730
Identification Chart ACD Group 0 731
Identification Chart ACD Group 1 732
Identification Chart ACD Group 2 733
Identification Chart ACD Group 3 734
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 735
Identification Chart 735
Description 736
Identification Chart ACD Group 0 737
Identification Chart ACD Group 1 738
Identification Chart ACD Group 2 739
Identification Chart ACD Group 3 740
SERVICE PC (LAPTOP COMPUTER) 741
Connecting Remote Start Tool 741
Connecting Remote Start Tool (Service Tool) 741
CALIBRATION 743
Description 743
Actuator Testing 743
Lift And Tilt Calibration (SJC) 746
Hydrostatic Pump Calibration (SJC) 748
Lift And Tilt Calibration (ACS) 753
STEERING DRIFT COMPENSATION 755
Description 755
Operation 755
FLYWHEEL RPM SENSOR 757
Description 757
Adjusting 757
CONTROL PANEL SETUP 759
Right Panel Setup (Deluxe Instrumentation Panel) 759
Attachment Control Information (Deluxe Instrumentation Panel) 760
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 761
Password Description 761
Changing The Owner Password 761
Changing The User Passwords 762
Password Lockout Feature 762
PASSWORD SETUP (KEYLESS START PANEL) 763
Password Description 763
Changing The Owner Password 763
Password Lockout Feature 763
MAINTENANCE CLOCK 765
Description 765
Setup 766
Reset 769
BACK-UP ALARM SYSTEM 771
Description 771
Inspecting 771
Adjusting Switch Position 772
Troubleshooting (Standard And ACS) 773
Troubleshooting (Joystick) 774
Alarm Removal And Installation 775
Switch Removal And Installation 775
ENGINE SERVICE 777
ENGINE INFORMATION 781
Description 781
Specifications 782
Torque Values 786
Troubleshooting 786
Engine Removal And Installation 788
Engine Mount Replacement 795
Compression – Checking 796
ENGINE SPEED CONTROL 797
Removal And Installation 797
ENGINE SPEED CONTROL (SJC) 799
Removal And Installation 799
Disassembly And Assembly 801
MUFFLER 803
Removal And Installation 803
AIR CLEANER 805
Housing Removal And Installation 805
ENGINE COOLING SYSTEM 807
Radiator Removal And Installation 807
Hydraulic Fan Description (S/N A3L329999 & Below And A3L429999 & Below) 810
Hydraulic Fan Disassembly And Assembly (S/N A3L329999 & Below And A3L429999 & Below) 810
Blower Housing Removal And Installation (S/N A3L329999 & Below And A3L429999 & Below) 811
Fan Removal And Installation (S/N A3L329999 & Below And A3L429999 & Below) 813
Hydraulic Fan Motor Removal And Installation (S/N A3L329999 & Below And A3L429999 & Below) 813
Hydraulic Fan Description (S/N A3L330001 & Above And A3L430001 & Above) 814
Hydraulic Fan Disassembly And Assembly (S/N A3L330001 & Above And A3L430001 & Above) 814
Blower Housing Removal And Installation (S/N A3L330001 & Above And A3L430001 & Above) 816
Fan Removal And Installation (S/N A3L330001 & Above And A3L430001 & Above) 818
Hydraulic Fan Motor Removal And Installation (S/N A3L330001 & Above And A3L430001 & Above) 818
Water Pump Removal And Installation 819
Water Pump Disassembly And Assembly 819
Thermostat Housing Removal And Installation 820
Thermostat – Checking 821
LUBRICATION SYSTEM 823
Oil Pan Removal And Installation 823
Relief Valve – Testing 824
Oil Pump Inspection 824
Oil Filter Cooler Removal And Installation 825
Engine Oil Pressure – Testing 826
FUEL SYSTEM 827
Fuel Shutoff Solenoid – Checking 827
Fuel Shutoff Solenoid Removal And Installation 827
Fuel Injection Pump – Checking 828
Fuel Injection Pump Assembly Removal And Installation 829
Governor Housing Disassembly And Assembly 832
Governor Disassembly And Assembly 834
Fuel Camshaft Removal And Installation 836
Fuel Injection Pump Removal And Installation 839
Fuel Injection Pump – Timing 841
Fuel Injector Removal And Installation 843
Fuel Injector Nozzle Pressure – Checking 845
Nozzle Spray Condition 845
Valve Seat Tightness 846
CYLINDER HEAD 847
Glow Plugs – Testing 847
Glow Plugs Removal And Installation 848
Valve Clearance Adjustment 849
Valve Timing – Checking 850
Cylinder Head Removal And Installation 851
Cylinder Head Disassembly And Assembly 854
Cylinder Head – Servicing 854
Cylinder Head Top Clearance 855
Valve Guide – Checking 855
Valve Guide Removal And Installation 856
Reconditioning The Valve And Valve Seat 856
Valve Spring 858
Valve Tappets 859
Rocker Arm And Shaft – Checking 860
Bridge Arm And Bridge Arm Shaft – Checking 860
Bridge Arm Shaft Removal And Installation 861
Push Rod Alignment – Checking 862
CRANKSHAFT AND PISTONS 863
Piston And Connecting Rod Removal And Installation 863
Piston And Connecting Rod – Servicing 865
Cylinder Bore – Checking 869
Connecting Rod Alignment 869
Crankshaft Gear Removal And Installation 870
Crankshaft And Bearings Removal And Installation 871
Crankshaft And Bearings – Servicing 874
CAMSHAFT AND TIMING GEARS 879
Timing Gearcase Cover Removal 879
Timing Gearcase Cover Installation 880
Timing Gears Backlash – Checking 883
Idler Gear And Camshaft Removal And Installation 883
Camshaft – Servicing 884
Idler Gear And Shaft – Servicing 885
TURBOCHARGER 887
Description 887
Testing 887
Removal And Installation 888
FLYWHEEL AND HOUSING 889
Flywheel Removal And Installation 889
Ring Gear Removal And Installation 890
Housing Removal And Installation 891
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 893
Description 893
Testing 894
Removal And Installation 897
Disassembly And Assembly 898
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 899
AIR CONDITIONING SYSTEM FLOW 901
Description 901
Chart 902
Components 903
Safety Equipment 906
REGULAR MAINTENANCE 907
Filters 907
Compressor Drive Belt Adjustment 907
Compressor Drive Belt Replacement 908
Condenser 908
Air Conditioning Lubrication 908
Air Conditioning Service Chart 909
Evaporator / Heater Coil 910
TROUBLESHOOTING 911
Blower Motor Does Not Operate 911
Blower Motor Operates Normally, But Air Flow Is Insufficient 911
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 911
The Compressor Does Not Operate At All, Or Operates Improperly 911
Gauge Pressure Related Troubleshooting 912
Troubleshooting Tree 914
Temperature / Pressure Chart 918
Poor A/C Performance 919
HVAC Repair And Leaks 920
Electrical System 921
Engine Coolant Bypassing The Heater Valve 928
Heater Valve Not Opening Or Closing 929
SYSTEM CHARGING AND RECLAMATION 931
Refrigerant Identification 931
Reclamation And Charging With Recovery / Charging Unit 932
Charging With A Manifold Gauge Set 934
COMPRESSOR 937
Removal And Installation 937
Oil 939
Oil Check 939
Clutch Disassembly And Assembly 941
CONDENSER 945
Removal And Installation 945
RECEIVER / DRIER 947
Receiver / Drier Removal And Installation 947
Pressure Relief Valve Removal And Installation 949
Pressure Switch Removal And Installation 950
Schraeder® Valve Removal And Installation 950
EVAPORATOR / HEATER UNIT 951
Removal And Installation 951
THERMOSTAT 953
Description 953
Removal And Installation 954
EXPANSION VALVE 955
Removal And Installation 955
EVAPORATOR COIL 957
Removal And Installation 957
HEATER COIL 959
Removal And Installation With A/C 959
Removal And Installation Without A/C 961
BLOWER FAN 963
Removal And Installation 963
Disassembly And Assembly 965
Connector Identification 967
HEATER VALVE 969
Removal And Installation 969
Disassembly And Assembly 970
SPECIFICATIONS 971
(S160) LOADER SPECIFICATIONS 973
Machine Dimensions 973
Performance 974
Engine 974
Drive System 974
Controls 975
Hydraulic System 975
Electrical 976
Capacities 976
Tires 976
TORQUE SPECIFICATIONS FOR BOLTS 977
Torque For General SAE Bolts 977
Torque For General Metric Bolts 978
HYDRAULIC CONNECTION SPECIFICATIONS 979
O-ring Face Seal Connection 979
Straight Thread O-ring Fitting 980
Tubelines And Hoses 980
Flare Fitting 981
Port Seal Fitting 982
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 983
Specifications 983
CONVERSIONS 985
Decimal And Millimeter Equivalent Chart 985
U S To Metric Conversion Chart 985
SERVICE TOOLS REQUIRED 987
Remote Start Tools 987
Hydraulic Tools 988
Mainframe And Drive Tools 990
Electrical Tools 991
Engine Tools 991
HVAC Tools 996
ALPHABETICAL INDEX 997

IMAGES PREVIEW OF THE MANUAL:

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