Bobcat S450 Skid-Steer Loader Service Manual 6990808 – PDF DOWNLOAD

Description

Bobcat S450 Skid-Steer Loader Service Manual 6990808 – PDF DOWNLOAD

FILE DETAILS:

Bobcat S450 Skid-Steer Loader Service Manual 6990808 – PDF DOWNLOAD

Language : English
Pages : 994
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S450 Skid-Steer Loader Service Manual 6990808 – PDF DOWNLOAD

S/N AV9V11001 & Above
S/N B1E611001 & 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 S450 Skid-Steer Loader Service Manual 6990808 – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
Avoid Silica Dust 11
FIRE PREVENTION 12
Maintenance 12
Operation 12
Electrical 12
Hydraulic System 12
Fueling 12
Starting 12
Spark Arrester Exhaust System 12
Welding And Grinding 13
Fire Extinguishers 13
SERIAL NUMBER LOCATIONS 14
Loader Serial Number 14
Engine Serial Number 14
DELIVERY REPORT 15
LOADER IDENTIFICATION 16
SAFETY AND MAINTENANCE 17
LIFTING AND BLOCKING THE LOADER 21
Procedure 21
LIFT ARM SUPPORT DEVICE 23
Description 23
Installing 24
Removing 25
OPERATOR CAB 27
Description 27
Cab Door Sensor 27
Raising 28
Lowering 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 Communicator – MEL1566 37
Remote Start Procedure 37
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666 41
Description 41
Remote Start Tool (Service Tool) – 7022042 42
Loader Service Tool Harness – 6689747 43
Computer Service Tool Harness – 6689746 44
Remote Start Procedure 45
SERVICE SCHEDULE 49
Maintenance Intervals 49
ENGINE AIR CLEANER 51
Replacing Filters 51
ENGINE COOLING SYSTEM 53
Maintenance Platform 53
Cleaning 53
Checking And Adding Coolant 56
Removing And Replacing Coolant 57
FUEL SYSTEM 59
Fuel Specifications 59
Biodiesel Blend Fuel 59
Filling The Fuel Tank 60
Fuel Filters 61
Removing Air From The Fuel System 63
ENGINE LUBRICATION SYSTEM 65
Checking And Adding Engine Oil 65
Engine Oil Chart 65
Removing And Replacing Oil And Filter 66
HYDRAULIC / HYDROSTATIC SYSTEM 69
Checking And Adding Fluid 69
Hydraulic / Hydrostatic Fluid Chart 69
Removing And Replacing Hydraulic Fluid 70
Removing And Replacing Hydraulic / Hydrostatic Filter 73
Removing And Replacing Hydraulic Charge Filter 74
Replacing Reservoir Breather Cap 76
FINAL DRIVE TRANSMISSION (CHAINCASE) 77
Checking And Adding Fluid 77
Removing And Replacing Fluid 77
BOB-TACH (HAND LEVER) 79
Inspection And Maintenance 79
BOB-TACH (POWER) 81
Inspection And Maintenance 81
LUBRICATING THE LOADER 83
Lubrication Locations 83
TIRE MAINTENANCE 87
Wheel Nuts 87
Rotating 87
Mounting 88
SPARK ARRESTER MUFFLER 89
Cleaning Procedure 89
PIVOT PINS 91
Inspection And Maintenance 91
LOADER STORAGE AND RETURN TO SERVICE 93
Storage 93
Return To Service 93
STOPPING THE ENGINE AND LEAVING THE LOADER 95
Procedure 95
EMERGENCY EXIT 97
Rear Window Identification 97
Rear Window Removal (Latches) 97
Rear Window Removal (Rubber Cord) 97
External Access (Rear Window With Latches) 98
External Access (Rear Window With Rubber Cord) 98
Front Door 99
SEAT BELT 101
Inspection And Maintenance 101
HYDRAULIC SYSTEM 103
HYDRAULIC / HYDROSTATIC SCHEMATICS 107
HYDRAULIC SYSTEM INFORMATION 123
Glossary Of Hydraulic / Hydrostatic Symbols 123
Troubleshooting 127
CYLINDER (LIFT) 129
Testing 129
Removal And Installation 130
Parts Identification 132
Disassembly 133
Assembly 135
CYLINDER (TILT) 139
Testing 139
Removal And Installation 140
Base End Pivot Pin Removal And Installation 141
Parts Identification 142
Disassembly 143
Assembly 145
CYLINDER (LIFT) (AZNB11488 & ABOVE) 149
Parts Identification 149
Disassembly 150
Assembly 152
CYLINDER (TILT) (AZNB11488 & ABOVE) 157
Parts Identification 157
Disassembly 158
Assembly 160
CYLINDER (BOB-TACH) 165
Testing 165
Removal And Installation 166
Parts Identification 167
Disassembly 168
Assembly 170
MAIN RELIEF VALVE 173
Description 173
Testing 174
Adjusting 176
Removal And Installation 177
HYDRAULIC CONTROL VALVE (STANDARD) 179
Description 179
Removal And Installation 180
Mount Bracket Removal And Installation 183
Identification Chart 184
Lift Load Check Valve Removal And Installation 185
Load Check Valve Removal And Installation (Tilt And Auxiliary) 186
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 187
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 187
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 188
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 188
Port Relief Valve Removal And Installation 189
Plug Removal And Installation 191
Rubber Boot Removal And Installation 192
End Cap Block Removal And Installation 192
Lift Spool And Detent Removal And Installation 193
Tilt Spool Removal And Installation 201
Auxiliary Spool Removal And Installation 203
Auxiliary Solenoid Removal And Installation 204
Solenoid Removal And Installation 205
Lock Valve Removal And Installation 206
Lift Arm Bypass Orifice Removal And Installation 208
Main Relief Valve Removal And Installation 208
Check Valve Removal And Installation 209
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 211
Description 211
Removal And Installation 211
Actuator Removal And Installation (In Loader) 214
Actuator Removal And Installation (Out Of Loader) 216
Identification Chart 219
Mount Bracket Removal And Installation 220
Lift Load Check Valve Removal And Installation 220
Load Check Valve Removal And Installation (Tilt And Auxiliary) 221
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 222
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 222
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 223
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 223
Port Relief Valve Removal And Installation 224
Plug Removal And Installation 226
End Cap Block Removal And Installation 227
Lift Spool Removal And Installation 227
Lift Spool Disassembly And Assembly 229
Tilt Spool Removal And Installation 230
Auxiliary Spool Removal And Installation 232
Auxiliary Solenoid Removal And Installation 233
Solenoid Removal And Installation 234
Lock Valve Removal And Installation 235
Lift Arm Bypass Orifice Removal And Installation 237
Main Relief Valve Removal And Installation 237
Check Valve Removal And Installation 238
LIFT ARM BYPASS CONTROL VALVE 239
Description 239
Testing 239
Removal And Installation 240
Bracket Removal And Installation 241
Disassembly And Assembly 241
HYDRAULIC PUMP 243
Description 243
Pump Test At Quick Couplers 244
Direct Pump Test (Standard Section) 246
Direct Pump Test (Charge Section) 248
Removal And Installation 250
Hydraulic Pump Startup 252
Parts Identification 253
Disassembly And Assembly 254
HYDRAULIC / HYDROSTATIC FILTERS 255
Description 255
Housing Removal And Installation 255
HYDRAULIC FLUID RESERVOIR 257
Description 257
Removal And Installation 257
Hydraulic Fluid Screen 258
Gauge Removal And Installation 258
OIL COOLER 259
Removal And Installation 259
BUCKET POSITION VALVE 261
Description 261
Solenoid Removal And Installation 261
Solenoid Testing 262
Removal And Installation 262
Disassembly And Assembly 264
BOB-TACH (POWER) BLOCK (EARLIER MODELS) 265
Description 265
Removal And Installation 265
Disassembly And Assembly 267
BOB-TACH (POWER) BLOCK (LATER MODELS) 275
Description 275
Testing Relief Valve 275
Removal And Installation 277
Disassembly And Assembly 279
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 285
Description 285
Removal And Installation 286
Disassembly And Assembly (FFI/FI) 287
Disassembly And Assembly (FFH/FH) 289
HYDROSTATIC SYSTEM 291
HYDROSTATIC SYSTEM INFORMATION 293
Description 293
Troubleshooting 294
HYDROSTATIC DRIVE MOTOR 295
Description 295
Removal And Installation 295
Parts Identification 297
Disassembly And Assembly 298
Shaft Seal Replacement 304
CHARGE PRESSURE 305
Description 305
Testing 305
Adjusting 307
Sender Removal And Installation 309
HYDROSTATIC PUMP 311
Description 311
Removal And Installation 312
Hydrostatic Pump Startup 313
Replenishing / High Pressure Relief Valve Removal And Installation 314
Parts Identification (Left Half) 315
Parts Identification (Right Half) 316
Disassembly 317
Assembly 324
HYDROSTATIC PUMP (SJC) 331
Description 331
Hydraulic Controller Removal And Installation 332
Removal And Installation 334
Hydrostatic Pump Startup 335
Parts Identification 336
High Pressure Relief And Bypass Valve 337
Charge Relief Valve 338
Disassembly And Assembly 339
Mechanical Neutral Adjustment 352
Hydraulic Controller Neutral Adjustment 354
DRIVE BELT 359
Belt Adjustment 359
Belt Replacement 359
Tensioner Pulley Removal And Installation 361
Tensioner Pulley Disassembly And Assembly 363
DRAIN MANIFOLD 365
Description 365
Drain Manifold Removal And Installation 365
DRIVE SYSTEM 367
BRAKE 369
Description 369
Disc Removal And Installation 369
DRIVE COMPONENTS 371
Description 371
Axle Seal Removal And Installation 372
Axle, Sprocket And Bearings Removal And Installation 374
Chain Removal And Installation 378
CHAINCASE 381
Description 381
Front Cover Removal And Installation 381
Center Cover Removal And Installation 382
MAINFRAME 383
SEAT BAR 387
Description 387
Removal And Installation 387
Disassembly And Assembly 388
Compression Spring Disassembly And Assembly 389
OPERATOR CAB 391
Gas Spring Removal And Installation 391
Gas Spring Bracket Disassembly And Assembly 392
Removal And Installation 392
OPERATOR SEAT 395
Removal And Installation 395
Seat Belt Removal And Installation (Retractable) 395
Seat Belt And Bracket Removal And Installation (Standard) 396
Seat Belt Bracket Removal And Installation 396
OPERATOR SEAT (SUSPENSION) 397
Removal And Installation 397
Slide Rail Removal And Installation 397
Seat Belt Removal And Installation 398
Lower Cushion Removal 398
Lower Cushion Installation 399
Back Cushion Removal And Installation 399
Shock Removal And Installation 400
3-Point Seat Belt Removal And Installation 400
BOB-TACH (HAND LEVER) 403
Description 403
Removal And Installation 403
Lever And Wedge Disassembly And Assembly 405
Pivot Pin Bushing And Seal Removal And Installation 407
BOB-TACH (POWER) 409
Description 409
Removal And Installation 409
Lever And Wedge Disassembly And Assembly 411
Pivot Pin Bushing And Seal Removal And Installation 414
LIFT ARMS 415
Removal And Installation 415
REAR GRILLE 419
Removing 419
Installing 419
REAR DOOR (TAILGATE) 421
Removal And Installation 421
Striker Removal And Installation 422
Striker Disassembly And Assembly 422
Striker Adjusting 423
Latch Removal And Installation 423
FUEL TANK 425
Removal And Installation 425
Fuel Fill Screen Removal And Installation 427
Fuel Level Sender Removal And Installation 427
CONTROL PEDALS AND LINKAGES 429
Description 429
Pedal Removal And Installation 429
Linkage Removal And Installation 430
Pedal (Adjusting) 431
Floor Pan Removal And Installation 432
CONTROL PEDALS AND LINKAGES (ACS) 433
Description 433
Pedal Removal And Installation 433
Linkage Removal And Installation 434
Pedal (Adjusting) 434
Floor Pan Removal And Installation 435
CONTROL PEDALS AND LINKAGES (SJC) 437
Description 437
CONTROL PANEL 439
Description 439
Removal And Installation 440
Disassembly And Assembly 441
Linkage Removal And Installation 443
Pintle Arm Disassembly And Assembly 447
Linkage Neutral (Adjusting) 448
Linkage Travel (Adjusting) 452
Shock Removal And Installation 456
CONTROL PANEL (SJC) 457
Description 457
Removal And Installation 457
CONTROL HANDLE / LEVER 459
Description 459
Lever Removal And Installation 459
Boot Removal And Installation 460
CONTROL HANDLE / LEVER (ACS) 461
Description 461
Handle Sensor Removal And Installation 461
Handle Removal And Installation 464
Handle Disassembly And Assembly 465
Lever Removal And Installation 465
Boot Removal And Installation 466
CONTROL HANDLE / LEVER (SJC) 467
Description 467
Joystick Testing 467
Joystick Removal And Installation 468
WINDOW (REAR) 469
Rear Window Identification 469
Removal (Rubber Cord) 469
Installation (Rubber Cord) 470
Removal And Installation (Latches) 472
Disassembly And Assembly (Latches) 472
WINDOW (TOP) 473
Removal And Installation 473
WINDOW (SIDE) 475
Removal And Installation 475
CAB DOOR 477
Description 477
Removal And Installation 477
Disassembly And Assembly 478
Aligning 479
Adjusting 480
Checking Operation 480
ARMREST 481
Description 481
Removal And Installation 482
Disassembly And Assembly 483
LEFT SIDE LOWER PANEL 485
Removal And Installation 485
Disassembly And Assembly 487
RIGHT SIDE LOWER PANEL 489
Removal And Installation 489
Disassembly And Assembly 490
HEADLINER 493
Removal And Installation 493
ELECTRICAL SYSTEM AND ANALYSIS 495
ELECTRICAL SCHEMATICS 501
ELECTRICAL SYSTEM INFORMATION 627
Glossary Of Electrical Symbols 627
Standard Cab Harness Connectors 630
Deluxe Cab Harness Connectors 631
Mainframe / Engine Harness Connectors – Manual Controls (Earlier Models) 632
Mainframe / Engine Harness Connectors – SJC/ACS Controls (Earlier Models) 633
Mainframe / Engine Harness Connectors – Manual Controls (Later Models) 634
Mainframe / Engine Harness Connectors – SJC/ACS Controls (Later Models) 635
Description 636
Fuse And Relay Location / Identification 636
Troubleshooting 640
Solenoid Testing 641
BATTERY 643
Servicing 643
Maintaining Battery Charge Level 643
Battery Service During Machine Storage 643
Battery Testing 644
Battery Charging 644
Using A Booster Battery (Jump Starting) 645
Removal And Installation 646
ALTERNATOR 651
Belt Adjustment 651
Belt Replacement 651
Charging System Inspection 652
Alternator Voltage Testing 653
Low Voltage Testing 653
High Voltage Testing 654
Removal And Installation 655
Parts Identification 656
STARTER 657
Testing 657
Removal And Installation 657
Parts Identification 658
INSTRUMENT PANELS 659
Left Panel 659
Display Screen 661
Right Panel (Standard Key Panel) 662
Right Panel (Keyless Start Panel) 663
Right Panel (Deluxe Instrumentation Panel) 664
Left Switch Panel 666
Right Switch Panel 666
Left Side Lower Panel 667
Right Side Lower Panel 667
Left Panel Removal And Installation 668
Right Panel (Standard Key Panel) Removal And Installation 668
Right Panel (Keyless Start Panel) Removal And Installation 669
Right Panel (Deluxe Instrumentation Panel) Removal And Installation 669
Key Switch Disassembly And Assembly 670
Alarm Disassembly And Assembly 670
Left Switch Panel Removal And Installation 671
Right Switch Panel Removal And Installation 671
LIGHTS 673
Front Removal And Installation 673
Rear Removal And Installation 674
Cab Light Removal And Installation 674
BOBCAT CONTROLLERS (ACS AND AUXILIARY) 675
Description 675
Connector And Wire Identification 676
Removal And Installation 680
BOBCAT CONTROLLER (GATEWAY) 681
Description 681
Connector Identification 682
Removal And Installation 685
BOBCAT CONTROLLER (SJC) (DRIVE) 687
Description 687
Connector Identification 688
Removal And Installation 690
DIAGNOSTIC SERVICE CODES 691
Viewing Service Codes 691
Service Codes List 692
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 699
Description 699
Inspecting The BICS™ (Engine STOPPED – Key ON) 700
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 700
Inspecting The Seat Bar Sensor (Engine RUNNING) 700
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 700
Inspecting The Lift Arm Bypass Control 700
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) 700
Troubleshooting 701
SEAT BAR SENSOR 703
Description 703
Troubleshooting 703
Testing 704
Removal 705
Installation 707
Bobcat Interlock Control System (BICS™) Circuit Test 708
TRACTION LOCK 711
Description 711
Troubleshooting 712
Inspecting 713
CONTROL SYSTEM (ACS) 715
Description 715
Troubleshooting 716
Handle Sensor Connector Disassembly And Assembly 717
Switch Handle Removal 718
Switch Handle Installation 720
Actuator Connector Disassembly And Assembly 723
Handle Lock Solenoid Removal And Installation 724
Handle Lock Solenoid Disassembly And Assembly 724
Foot Sensor Removal And Installation 725
Foot Sensor Disassembly And Assembly 726
Foot Sensor Lock Solenoid Removal And Installation 726
ELECTRICAL / HYDRAULIC CONTROLS 727
Identification Chart 727
Description 728
Identification Chart ACD Group 0 729
Identification Chart ACD Group 1 730
Identification Chart ACD Group 2 731
Identification Chart ACD Group 3 732
ELECTRICAL / HYDRAULIC CONTROLS (ACS) 733
Identification Chart 733
Description 734
Identification Chart ACD Group 0 735
Identification Chart ACD Group 1 736
Identification Chart ACD Group 2 737
Identification Chart ACD Group 3 738
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 739
Identification Chart 739
Description 740
Identification Chart ACD Group 0 741
Identification Chart ACD Group 1 742
Identification Chart ACD Group 2 743
Identification Chart ACD Group 3 744
SERVICE PC (LAPTOP COMPUTER) 745
Connecting Remote Start Tool 745
Connecting Remote Start Tool (Service Tool) 745
CALIBRATION 747
Description 747
Actuator Testing 747
Lift And Tilt Calibration (SJC) 750
Hydrostatic Pump Calibration (SJC) 752
Lift And Tilt Calibration (ACS) 757
STEERING DRIFT COMPENSATION (OPERATOR MODE) 759
Description 759
Operation 759
STEERING DRIFT COMPENSATION (SERVICE MODE) 761
Description 761
Operation 761
FLYWHEEL RPM SENSOR 763
Description 763
Removal 763
Installation 764
CONTROL PANEL SETUP 765
Right Panel Setup (Deluxe Instrumentation Panel) 765
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 769
Password Description 769
Changing The Owner Password 769
Changing The User Passwords 770
Password Lockout Feature 770
PASSWORD SETUP (KEYLESS START PANEL) 771
Password Description 771
Changing The Owner Password 771
Password Lockout Feature 771
MAINTENANCE CLOCK 773
Description 773
Setup 774
Reset 777
BACK-UP ALARM SYSTEM 779
Description 779
Inspecting 779
Adjusting Switch Position 780
Troubleshooting (Standard And ACS) 781
Troubleshooting (Joystick) 782
Alarm Removal And Installation 783
Switch Removal And Installation 783
FRONT HORN 785
Removal And Installation 785
Troubleshooting 786
Troubleshooting (Joystick) 787
ENGINE SERVICE 789
ENGINE INFORMATION 793
Description 793
Specifications 794
Torque Values 797
Troubleshooting 797
Engine Removal And Installation 799
Engine Mount Replacement 808
Compression – Testing 809
ENGINE SPEED CONTROL (HAND) 811
Removal And Installation 811
Disassembly And Assembly 811
Cable Removal And Installation 812
ENGINE SPEED CONTROL (FOOT) (SJC) 813
Description 813
Removal And Installation 813
Disassembly and Assembly 815
Pedal (Adjusting) 816
Floor Pan Removal And Installation 816
MUFFLER 817
Removal And Installation 817
AIR CLEANER 819
Housing Removal And Installation 819
ENGINE COOLING SYSTEM 821
Radiator / Oil Cooler Removal And Installation 821
Hydraulic Fan Description 824
Fan Duct Removal And Installation 824
Hydraulic Fan Motor Assembly Removal And Installation (Earlier Models) 825
Hydraulic Fan Motor Removal And Installation (Earlier Models) 826
Hydraulic Fan Motor Disassembly And Assembly (Earlier Models) 827
Hydraulic Fan Motor Assembly Removal And Installation (Later Models) 829
Fan Removal And Installation (Later Models) 830
Hydraulic Fan Motor Removal And Installation (Later Models) 831
Hydraulic Fan Motor Disassembly And Assembly (Later Models) 832
Water Pump Removal And Installation 838
Water Pump Disassembly And Assembly 838
Thermostat Housing Removal And Installation 839
Thermostat – Testing 840
LUBRICATION SYSTEM 841
Oil Pan Removal And Installation 841
Relief Valve – Inspection 841
Oil Pump Removal And Installation 842
Oil Pump Inspection 842
Engine Oil Pressure – Testing 843
FUEL SYSTEM 845
Fuel Shutoff Solenoid – Testing 845
Fuel Shutoff Solenoid Removal And Installation 845
Fuel Injection Pump – Testing 846
Fuel Injection Pump Removal And Installation 847
Governor Disassembly And Assembly 851
Fuel Camshaft Removal And Installation 852
Fuel Injection Pump – Timing 852
Fuel Injector Removal And Installation 854
Fuel Injector Nozzle Pressure – Checking 855
Nozzle Spray Condition 856
Valve Seat Tightness 856
CYLINDER HEAD 857
Glow Plugs – Testing 857
Glow Plugs Removal And Installation 857
Valve Clearance Adjustment 858
Valve Timing – Inspecting 859
Cylinder Head Removal And Installation 860
Cylinder Head Disassembly And Assembly 863
Cylinder Head – Servicing 863
Cylinder Head Top Clearance 864
Valve Guide – Inspecting 864
Valve Guide Removal And Installation 865
Reconditioning The Valve And Valve Seat 865
Valve Spring 867
Valve Tappets 868
Rocker Arm And Shaft – Inspecting 868
Push Rod Alignment – Inspecting 869
CRANKSHAFT AND PISTONS 871
Piston And Connecting Rod Removal And Installation 871
Piston And Connecting Rod – Servicing 872
Cylinder Bore – Inspecting 875
Connecting Rod Alignment 875
Crankshaft Gear Removal And Installation 876
Crankshaft And Bearings Removal And Installation 876
Crankshaft And Bearings – Servicing 878
CAMSHAFT AND TIMING GEARS 883
Timing Gearcase Cover Removal And Installation 883
Timing Gears Backlash – Inspection 885
Idler Gear And Camshaft Removal And Installation 886
Camshaft – Servicing 887
Idler Gear And Shaft – Servicing 888
FLYWHEEL AND HOUSING 889
Flywheel Removal And Installation 889
Ring Gear Removal And Installation 889
Housing Removal And Installation 890
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 893
AIR CONDITIONING SYSTEM FLOW 895
Description 895
Chart 896
Components 897
Safety Equipment 900
REGULAR MAINTENANCE 901
Filters 901
Belt Adjustment 902
Belt Replacement 902
Air Conditioning Condenser 903
Air Conditioning Lubrication 903
Air Conditioning Service Chart 904
Evaporator / Heater Coil 905
TROUBLESHOOTING 907
Blower Motor Does Not Operate 907
Blower Motor Operates Normally, But Air Flow Is Insufficient 907
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 907
The Compressor Does Not Operate At All, Or Operates Improperly 907
Gauge Pressure Related Troubleshooting 908
Troubleshooting Tree 910
Temperature / Pressure Chart 914
Poor A/C Performance 916
HVAC Repair And Leaks 917
Electrical System 918
Engine Coolant Bypassing The Heater Valve 924
Heater Valve Not Opening Or Closing 925
SYSTEM CHARGING AND RECLAMATION 927
Refrigerant Identification 927
Reclamation And Charging With Recovery / Charging Unit 928
COMPRESSOR 931
Removal And Installation 931
Oil 932
Oil Check 933
CONDENSER 935
Removal And Installation 935
RECEIVER / DRIER 937
Receiver / Drier Removal And Installation 937
Pressure Switch Removal And Installation 938
Schrader® Valve Removal And Installation 939
EVAPORATOR / HEATER UNIT 941
Removal And Installation 941
THERMOSTAT 943
Description 943
Removal And Installation 944
EXPANSION VALVE 945
Removal And Installation 945
EVAPORATOR COIL 947
Removal And Installation 947
HEATER COIL 949
Removal And Installation 949
BLOWER FAN 951
Removal And Installation 951
Disassembly And Assembly 951
HEATER VALVE 955
Removal And Installation 955
SPECIFICATIONS 957
(S450) LOADER SPECIFICATIONS 959
Machine Dimensions 959
Performance 960
Engine 960
Drive System 961
Controls 961
Hydraulic System 962
Electrical System 963
Capacities 963
Tires 964
Environmental 964
Temperature Range 964
TECHNICAL SERVICE GUIDE SPECIFICATIONS 965
Engine 965
Engine Torques 965
Cooling System 965
Loader Torques 966
Hydraulic / Hydrostatic System 966
Fuel Consumption 966
TORQUE SPECIFICATIONS FOR BOLTS 967
Torque For General SAE Bolts 967
Torque For General Metric Bolts 968
HYDRAULIC CONNECTION SPECIFICATIONS 969
Straight Thread O-ring Fitting 969
Flare Fitting 970
Tubelines And Hoses 970
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 971
Specifications 971
CONVERSIONS 973
Decimal And Millimeter Equivalent Chart 973
U S To Metric Conversion Chart 973
SERVICE TOOLS REQUIRED 975
Remote Start Tools 975
Hydraulic Tools 976
Mainframe And Drive Tools 979
Electrical Tools 982
Engine Tools 983
HVAC Tools 988
ALPHABETICAL INDEX 989

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