Bobcat S510 Skid-Steer Loader Service Manual 6989666 – PDF DOWNLOAD

Description

Bobcat S510 Skid-Steer Loader Service Manual 6989666 – PDF DOWNLOAD

FILE DETAILS:

Bobcat S510 Skid-Steer Loader Service Manual 6989666 – PDF DOWNLOAD

Language : English
Pages : 1124
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S510 Skid-Steer Loader Service Manual 6989666 – PDF DOWNLOAD

S/N A3NJ11001 & Above
S/N B42411001 & 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 S510 Skid-Steer Loader Service Manual 6989666 – 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 25
Description 25
Installing 26
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 THE LOADER ON A TRAILER 35
Loading And Unloading 35
Fastening 35
TOWING THE LOADER 37
Procedure 37
REMOTE START TOOL – MEL1563 39
Remote Start Tool – MEL1563 39
Service Tool Harness Communicator – MEL1566 41
Remote Start Procedure 41
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
SERVICE SCHEDULE 53
Maintenance Intervals 53
ENGINE AIR CLEANER 55
Replacing Filters 55
ENGINE COOLING SYSTEM (EARLIER MODELS) 57
Maintenance Platform 57
Cleaning 58
Checking And Adding Coolant 59
Removing And Replacing Coolant 60
ENGINE COOLING SYSTEM (LATER MODELS) 61
Maintenance Platform 61
Cleaning 61
Checking And Adding Coolant 63
Removing And Replacing Coolant 64
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
HYDRAULIC / HYDROSTATIC SYSTEM (EARLIER MODELS) 73
Checking And Adding Fluid 73
Hydraulic / Hydrostatic Fluid Chart 73
Removing And Replacing Hydraulic Fluid 74
Removing And Replacing Hydraulic / Hydrostatic Filter 76
Removing And Replacing Hydraulic Charge Filter 77
Replacing Reservoir Breather Cap 78
HYDRAULIC / HYDROSTATIC SYSTEM (LATER MODELS) 79
Checking And Adding Fluid 79
Hydraulic / Hydrostatic Fluid Chart 79
Removing And Replacing Hydraulic Fluid 80
Removing And Replacing Hydraulic / Hydrostatic Filter 82
Removing And Replacing Hydraulic Charge Filter 83
Replacing Reservoir Breather Cap 84
FINAL DRIVE TRANSMISSION (CHAINCASE) 85
Checking And Adding Fluid 85
Removing And Replacing Fluid 85
BOB-TACH (HAND LEVER) 87
Inspection And Maintenance 87
BOB-TACH (POWER) 89
Inspection And Maintenance 89
LUBRICATING THE LOADER 91
Lubrication Locations 91
TIRE MAINTENANCE 95
Wheel Nuts 95
Rotating 95
Mounting 96
SPARK ARRESTER MUFFLER 97
Cleaning Procedure 97
PIVOT PINS 99
Inspection And Maintenance 99
LOADER STORAGE AND RETURN TO SERVICE 101
Storage 101
Return To Service 101
STOPPING THE ENGINE AND LEAVING THE LOADER 103
Procedure 103
EMERGENCY EXIT 105
Rear Window Identification 105
Rear Window Removal (Latches) 105
Rear Window Removal (Rubber Cord) 105
External Access (Rear Window With Latches) 106
External Access (Rear Window With Rubber Cord) 106
Front Door 107
SEAT BELT 109
Inspection And Maintenance 109
HYDRAULIC SYSTEM 111
HYDRAULIC / HYDROSTATIC SCHEMATICS 115
HYDRAULIC SYSTEM INFORMATION 135
Glossary Of Hydraulic / Hydrostatic Symbols 135
Troubleshooting 139
CYLINDER (LIFT) 141
Testing 141
Removal And Installation 142
Parts Identification 145
Disassembly 146
Assembly 148
CYLINDER (TILT) 153
Testing 153
Removal And Installation 154
Base End Pivot Pin Removal And Installation 155
Parts Identification 156
Disassembly 157
Assembly 159
CYLINDER (BOB-TACH) 163
Testing 163
Removal And Installation 164
Parts Identification 165
Disassembly 166
Assembly 167
MAIN RELIEF VALVE 171
Description 171
Testing 172
Adjusting 174
Removal And Installation 175
HYDRAULIC CONTROL VALVE (STANDARD) 177
Description 177
Removal And Installation 178
Mount Bracket Removal And Installation 181
Identification Chart 182
Lift Load Check Valve Removal And Installation 183
Load Check Valve Removal And Installation (Tilt And Auxiliary) 184
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 185
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 185
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 186
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 186
Port Relief Valve Removal And Installation 187
Plug Removal And Installation 189
Rubber Boot Removal And Installation 190
End Cap Block Removal And Installation 190
Lift Spool And Detent Removal And Installation 191
Tilt Spool Removal And Installation 199
Auxiliary Spool Removal And Installation 201
Auxiliary Solenoid Removal And Installation 202
Solenoid Removal And Installation 203
Lock Valve Removal And Installation 204
Lift Arm Bypass Orifice Removal And Installation 206
Main Relief Valve Removal And Installation 206
Check Valve Removal And Installation 207
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 209
Description 209
Removal And Installation 209
Actuator Removal And Installation (In Loader) 213
Actuator Removal And Installation (Out Of Loader) 215
Identification Chart 218
Mount Bracket Removal And Installation 219
Lift Load Check Valve Removal And Installation 219
Load Check Valve Removal And Installation (Tilt And Auxiliary) 220
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 221
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 221
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 222
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 222
Port Relief Valve Removal And Installation 223
Plug Removal And Installation 225
End Cap Block Removal And Installation 226
Lift Spool Removal And Installation 226
Lift Spool Disassembly And Assembly 228
Tilt Spool Removal And Installation 229
Auxiliary Spool Removal And Installation 231
Auxiliary Solenoid Removal And Installation 232
Solenoid Removal And Installation 233
Lock Valve Removal And Installation 234
Lift Arm Bypass Orifice Removal And Installation 236
Main Relief Valve Removal And Installation 236
Check Valve Removal And Installation 237
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
OIL COOLER (EARLIER MODELS) 259
Description 259
Removal And Installation 259
OIL COOLER (LATER MODELS) 261
Removal And Installation 261
BUCKET POSITION VALVE 263
Description 263
Solenoid Removal And Installation 263
Solenoid Testing 264
Removal And Installation 265
Disassembly And Assembly 267
REAR AUXILIARY DIVERTER VALVE 269
Description 269
Solenoid Testing 269
Removal And Installation 270
Disassembly And Assembly 271
BOB-TACH (POWER) BLOCK (EARLIER MODELS) 277
Description 277
Removal And Installation 277
Disassembly And Assembly 279
BOB-TACH (POWER) BLOCK (LATER MODELS) 287
Description 287
Testing Relief Valve 288
Removal And Installation 290
Disassembly And Assembly 292
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 297
Description 297
Removal And Installation 298
Disassembly And Assembly (FFI/FI) 298
Disassembly And Assembly (FFH/FH) 300
AUTOMATIC RIDE CONTROL 303
Description 303
Removal and Installation 304
Checking The Pressure In The Accumulator 307
Adding Nitrogen To The Accumulator 309
HYDROSTATIC SYSTEM 311
HYDROSTATIC SYSTEM INFORMATION 313
Description 313
Troubleshooting 314
HYDROSTATIC DRIVE MOTOR 315
Description 315
Removal And Installation 315
Parts Identification 318
Disassembly And Assembly 319
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 323
Description 323
Removal And Installation (Left Side) 324
Removal And Installation (Right Side) 327
Parts Identification 330
Disassembly 331
Assembly 344
HYDROSTATIC MOTOR CARRIER 359
Description 359
Shaft Seal Removal And Installation 360
Removal And Installation 362
Parts Identification 364
Disassembly 365
Assembly 367
HYDROSTATIC MOTOR CARRIER (TWO-SPEED) 371
Description 371
Shaft Seal Removal And Installation 372
Removal And Installation 374
Parts Identification 376
Disassembly 377
Assembly 379
CHARGE PRESSURE 383
Description 383
Testing 384
Adjusting 385
Sender Removal And Installation 387
HYDROSTATIC PUMP 389
Description 389
Removal And Installation 390
Hydrostatic Pump Startup 391
Replenishing / High Pressure Relief Valve Removal And Installation 392
Parts Identification (Left Half) 393
Parts Identification (Right Half) 394
Disassembly 395
Assembly 402
HYDROSTATIC PUMP (SJC) 409
Description 409
Hydraulic Controller Removal And Installation 410
Removal And Installation 412
Hydrostatic Pump Startup 414
Parts Identification 415
High Pressure Relief And Bypass Valve 416
Charge Relief Valve 417
Disassembly And Assembly 418
Mechanical Neutral Adjustment 431
Hydraulic Controller Neutral Adjustment 434
DRIVE BELT 437
Belt Adjustment 437
Belt Replacement 438
TWO-SPEED 441
Valve Block Removal And Installation 441
Valve Block Disassembly And Assembly 442
DRAIN MANIFOLD 443
Description 443
Drain Manifold Removal And Installation 443
DRIVE SYSTEM 445
BRAKE 447
Description 447
Disc Removal And Installation 447
DRIVE COMPONENTS 449
Description 449
Axle Seal Removal And Installation 450
Axle, Sprocket And Bearings Removal And Installation 452
Chain Removal And Installation 457
CHAINCASE 459
Description 459
Front Cover Removal And Installation 459
Center Cover Removal And Installation 460
Rear Cover Removal And Installation 461
MAINFRAME 463
SEAT BAR 467
Description 467
Removal And Installation 467
Disassembly And Assembly 468
Compression Spring Disassembly And Assembly 469
OPERATOR CAB 471
Gas Spring Removal And Installation 471
Gas Spring Bracket Disassembly And Assembly 472
Removal And Installation 472
OPERATOR SEAT 475
Removal And Installation 475
Seat Belt Removal And Installation (Retractable) 475
Seat Belt And Bracket Removal And Installation (Standard) 476
Seat Belt Bracket Removal And Installation 476
OPERATOR SEAT (SUSPENSION) 477
Removal And Installation 477
Slide Rail Removal And Installation 477
Seat Belt Removal And Installation 478
Lower Cushion Removal 478
Lower Cushion Installation 479
Back Cushion Removal And Installation 479
Shock Removal And Installation 480
3-Point Seat Belt Removal And Installation 480
BOB-TACH (HAND LEVER) 483
Description 483
Removal And Installation 483
Lever And Wedge Disassembly And Assembly 485
Pivot Pin Bushing And Seal Removal And Installation 487
BOB-TACH (POWER) 489
Description 489
Removal And Installation 489
Lever And Wedge Disassembly And Assembly 492
Pivot Pin Bushing And Seal Removal And Installation 494
LIFT ARMS 495
Removal And Installation 495
REAR GRILLE 497
Removing 497
Installing 497
REAR DOOR (TAILGATE) 499
Removal And Installation 499
Striker Removal And Installation 500
Striker Disassembly And Assembly 500
Striker Adjusting 501
Latch Removal And Installation 501
FUEL TANK 503
Removal And Installation 503
Fuel Level Sender Removal And Installation 506
Fuel Fill Screen Removal And Installation 506
CONTROL PEDALS AND LINKAGES 507
Description 507
Pedal Removal And Installation 507
Linkage Removal And Installation 508
Pedal (Adjusting) 509
Floor Pan Removal And Installation 510
CONTROL PEDALS AND LINKAGES (ACS) 511
Description 511
Pedal Removal And Installation 511
Linkage Removal And Installation 512
Pedal (Adjusting) 512
Floor Pan Removal And Installation 513
CONTROL PANEL 515
Description 515
Removal And Installation 516
Disassembly And Assembly 517
Linkage Removal And Installation 519
Pintle Arm Disassembly And Assembly 523
Linkage Neutral (Adjusting) 524
Linkage Travel (Adjusting) 528
Shock Removal And Installation 532
CONTROL PANEL (SJC) 533
Description 533
Removal And Installation 533
CONTROL HANDLE / LEVER 535
Description 535
Lever Removal And Installation 535
Boot Removal And Installation 536
CONTROL HANDLE / LEVER (ACS) 537
Description 537
Handle Sensor Removal And Installation 537
Handle Removal And Installation 540
Handle Disassembly And Assembly 541
Lever Removal And Installation 541
Boot Removal And Installation 542
CONTROL HANDLE / LEVER (SJC) 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
ACCESS PANEL (INSIDE) (SJC) 547
Removal And Installation (Left) 547
Removal And Installation (Right) 547
WINDOW (REAR) 549
Rear Window Identification 549
Rear Window Removal (Latches) 549
Rear Window Removal (Rubber Cord) 549
Disassembly And Assembly 550
External Access (Rear Window With Latches) 551
External Access (Rear Window With Rubber Cord) 551
WINDOW (TOP) 553
Removal And Installation 553
WINDOW (SIDE) 555
Removal And Installation 555
CAB DOOR 557
Description 557
Removal And Installation 557
Disassembly And Assembly 558
Aligning 559
Adjusting 560
Checking Operation 560
ARMREST 561
Description 561
Removal And Installation 562
Disassembly And Assembly 563
LEFT SIDE LOWER PANEL 565
Removal And Installation 565
Disassembly And Assembly 567
RIGHT SIDE LOWER PANEL 569
Removal And Installation 569
Disassembly And Assembly 570
HEADLINER 573
Removal And Installation 573
ELECTRICAL SYSTEM AND ANALYSIS 575
ELECTRICAL SCHEMATICS 581
ELECTRICAL SYSTEM INFORMATION 789
Glossary Of Electrical Symbols 789
Standard Cab Harness Connectors 792
Deluxe Cab Harness Connectors 793
Mainframe Harness Connectors – Manual Controls 794
Mainframe Harness Connectors – SJC 795
Description 796
Troubleshooting 797
Fuse And Relay Location / Identification 798
Solenoid Testing 800
BATTERY 801
Removal And Installation 801
Battery Maintenance 802
Maintaining Battery Charge Level 802
Battery Service During Machine Storage 802
Battery Testing 803
Battery Charging 803
Using A Booster Battery (Jump Starting) 804
ALTERNATOR BELT 805
Belt Adjustment 805
Belt Replacement 805
Alternator Voltage Testing 806
Low Voltage Testing 806
High Voltage Testing 807
Removal And Installation 808
Parts Identification 809
STARTER 811
Testing 811
Removal And Installation 811
Parts Identification 812
INSTRUMENT PANELS 813
Left Panel 813
Display Screen 815
Right Panel (Standard Key Panel) 816
Right Panel (Keyless Start Panel) 817
Right Panel (Deluxe Instrumentation Panel) 818
Left Switch Panel 820
Right Switch Panel 820
Left Side Lower Panel 821
Right Side Lower Panel 821
Left Panel Removal And Installation 822
Right Panel (Standard Key Panel) Removal And Installation 822
Right Panel (Keyless Start Panel) Removal And Installation 823
Right Panel (Deluxe Instrumentation Panel) Removal And Installation 823
Key Switch Disassembly And Assembly 824
Alarm Disassembly And Assembly 824
Left Switch Panel Removal And Installation 825
Right Switch Panel Removal And Installation 825
LIGHTS 827
Front Removal And Installation 827
Rear Removal And Installation 828
Cab Light Removal And Installation 828
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) 829
Description 829
Connector Identification 830
Removal And Installation 836
BOBCAT CONTROLLER (ACS) 837
Description 837
Connector And Wire Identification 838
Removal And Installation 839
BOBCAT CONTROLLER (SJC) (DRIVE) 841
Description 841
Connector Identification 842
Removal And Installation 844
DIAGNOSTIC SERVICE CODES 845
Viewing Service Codes 845
Service Codes List 846
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 853
Description 853
Inspecting The BICS™ (Engine STOPPED – Key ON) 854
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 854
Inspecting The Seat Bar Sensor (Engine RUNNING) 854
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 854
Inspecting The Lift Arm Bypass Control 854
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) 854
Troubleshooting 855
SEAT BAR SENSOR 857
Description 857
Troubleshooting 857
Testing 858
Removal 859
Installation 861
Bobcat Interlock Control System (BICS™) Circuit Test 862
TRACTION LOCK 865
Description 865
Troubleshooting 866
Inspecting 867
CONTROL SYSTEM (ACS) 869
Description 869
Troubleshooting 870
Handle Sensor Connector Disassembly And Assembly 871
Switch Handle Removal 872
Switch Handle Installation 874
Actuator Connector Disassembly And Assembly 877
Handle Lock Solenoid Removal And Installation 878
Handle Lock Solenoid Disassembly And Assembly 878
Foot Sensor Removal And Installation 879
Foot Sensor Disassembly And Assembly 880
Foot Sensor Lock Solenoid Removal And Installation 880
ELECTRICAL / HYDRAULIC CONTROLS 881
Identification Chart 881
Description 882
Identification Chart ACD Group 0 883
Identification Chart ACD Group 1 884
Identification Chart ACD Group 2 885
Identification Chart ACD Group 3 886
ELECTRICAL / HYDRAULIC CONTROLS (ACS) 887
Identification Chart 887
Description 888
Identification Chart ACD Group 0 889
Identification Chart ACD Group 1 890
Identification Chart ACD Group 2 891
Identification Chart ACD Group 3 892
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 893
Identification Chart 893
Description 894
Identification Chart ACD Group 0 895
Identification Chart ACD Group 1 896
Identification Chart ACD Group 2 897
Identification Chart ACD Group 3 898
SERVICE PC (LAPTOP COMPUTER) 899
Connecting Remote Start Tool 899
Connecting Remote Start Tool (Service Tool) 899
CALIBRATION 901
Description 901
Actuator Testing 901
Lift And Tilt Calibration (SJC) 904
Hydrostatic Pump Calibration (SJC) 906
Lift And Tilt Calibration (ACS) 911
STEERING DRIFT COMPENSATION (OPERATOR MODE) 913
Description 913
Operation 913
STEERING DRIFT COMPENSATION (SERVICE MODE) 915
Description 915
Operation 915
FLYWHEEL RPM SENSOR 917
Description 917
Removal 917
Installation 918
CONTROL PANEL SETUP 919
Right Panel Setup (Deluxe Instrumentation Panel) 919
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 923
Password Description 923
Changing The Owner Password 923
Changing The User Passwords 924
Password Lockout Feature 924
PASSWORD SETUP (KEYLESS START PANEL) 925
Password Description 925
Changing The Owner Password 925
Password Lockout Feature 925
MAINTENANCE CLOCK 927
Description 927
Setup 928
Reset 931
BACK-UP ALARM SYSTEM 933
Description 933
Inspection 933
Adjusting Switch Position 934
Troubleshooting (Standard And ACS) 935
Troubleshooting (Joystick) 936
Alarm Removal And Installation 937
Switch Removal And Installation 937
FRONT HORN 939
Removal And Installation 939
Troubleshooting 940
Troubleshooting (Joystick) 941
MACHINE IQ 943
Description 943
Removal And Installation 943
Procedure 944
ENGINE SERVICE 945
ENGINE INFORMATION 949
Description 949
Specifications 950
Torque Values 953
Troubleshooting 953
Engine Removal And Installation 955
Engine Mount Replacement 963
Compression – Testing 964
ENGINE SPEED CONTROL (HAND) 967
Removal And Installation 967
Disassembly And Assembly 967
Cable Removal And Installation 968
ENGINE SPEED CONTROL (FOOT) 969
Removal And Installation 969
Disassembly And Assembly 970
MUFFLER 973
Removal And Installation 973
AIR CLEANER 975
Housing Removal And Installation 975
ENGINE COOLING SYSTEM (EARLIER MODELS) 977
Radiator Removal And Installation 977
Hydraulic Fan Description 979
Fan Duct Removal And Installation 979
Hydraulic Fan Motor Assembly Removal And Installation 980
Hydraulic Fan Motor Removal And Installation 981
Hydraulic Fan Motor Disassembly And Assembly 983
Blower Housing Removal And Installation 984
Water Pump Removal And Installation 985
Water Pump Disassembly And Assembly 985
Thermostat Housing Removal And Installation 986
Thermostat – Testing 987
ENGINE COOLING SYSTEM (LATER MODELS) 989
Radiator / Oil Cooler Removal And Installation 989
Hydraulic Fan Description 992
Reversible Hydraulic Fan Description 992
Fan Duct Removal And Installation 992
Hydraulic Fan Motor Assembly Removal And Installation 993
Hydraulic Fan Motor Removal And Installation 994
Hydraulic Fan Motor Disassembly And Assembly 996
Blower Housing Removal And Installation 1004
Water Pump Removal And Installation 1005
Water Pump Disassembly And Assembly 1005
Thermostat Housing Removal And Installation 1006
Thermostat – Testing 1007
LUBRICATION SYSTEM 1009
Oil Pan Removal And Installation 1009
Relief Valve – Inspection 1009
Oil Pump Removal And Installation 1010
Oil Pump Inspection 1010
Engine Oil Pressure – Testing 1011
FUEL SYSTEM 1013
Fuel Shutoff Solenoid – Testing 1013
Fuel Shutoff Solenoid Removal And Installation 1013
Fuel Injection Pump – Testing 1014
Fuel Injection Pump Removal And Installation 1015
Governor Disassembly And Assembly 1019
Fuel Camshaft Removal And Installation 1020
Fuel Injection Pump – Timing 1020
Fuel Injector Removal And Installation 1022
Fuel Injector Nozzle Pressure – Testing 1023
Nozzle Spray Condition 1024
Valve Seat Tightness 1024
CYLINDER HEAD 1025
Glow Plugs – Testing 1025
Glow Plugs Removal And Installation 1025
Valve Clearance Adjustment 1026
Valve Timing – Inspecting 1027
Cylinder Head Removal And Installation 1028
Cylinder Head Disassembly And Assembly 1031
Cylinder Head – Servicing 1031
Cylinder Head Top Clearance 1032
Valve Guide – Inspecting 1032
Valve Guide Removal And Installation 1033
Reconditioning The Valve And Valve Seat 1033
Valve Spring 1035
Valve Tappets 1036
Rocker Arm And Shaft – Inspecting 1036
Push Rod Alignment – Inspecting 1037
CRANKSHAFT AND PISTONS 1039
Piston And Connecting Rod Removal And Installation 1039
Piston And Connecting Rod – Servicing 1040
Cylinder Bore – Inspecting 1043
Connecting Rod Alignment 1043
Crankshaft Gear Removal And Installation 1044
Crankshaft And Bearings Removal And Installation 1044
Crankshaft And Bearings – Servicing 1046
CAMSHAFT AND TIMING GEARS 1051
Timing Gearcase Cover Removal And Installation 1051
Timing Gears Backlash – Inspection 1053
Idler Gear And Camshaft Removal And Installation 1054
Camshaft – Servicing 1055
Idler Gear And Shaft – Servicing 1056
FLYWHEEL AND HOUSING 1057
Flywheel Removal And Installation 1057
Ring Gear Removal And Installation 1057
Housing Removal And Installation 1058
HEATING AND VENTILATION 1061
REGULAR MAINTENANCE 1063
Filters 1063
Heater Coil 1064
Troubleshooting 1065
TROUBLESHOOTING 1067
Blower Motor Does Not Operate 1067
Blower Motor Operates Normally, But Air Flow Is Insufficient 1067
Troubleshooting Tree 1068
Electrical System 1070
Engine Coolant Bypassing The Heater Valve 1073
Heater Valve Not Opening Or Closing 1074
HEATER UNIT 1075
Removal And Installation 1075
HEATER COIL 1077
Removal And Installation 1077
BLOWER FAN 1079
Removal And Installation 1079
Disassembly And Assembly 1079
HEATER VALVE 1083
Removal And Installation 1083
EVAPORATOR / HEATER COVER 1085
Removing 1085
Installing 1085
SPECIFICATIONS 1087
(S510) LOADER SPECIFICATIONS 1089
Machine Dimensions 1089
Performance 1090
Engine 1090
Drive System 1091
Controls 1091
Hydraulic System 1092
Electrical System 1093
Capacities 1093
Tires 1094
TECHNICAL SERVICE GUIDE SPECIFICATIONS 1095
Engine 1095
Engine Torques 1095
Cooling System 1095
Loader Torques 1096
Hydraulic / Hydrostatic System 1096
Fuel Consumption 1096
TORQUE SPECIFICATIONS FOR BOLTS 1097
Torque For General SAE Bolts 1097
Torque For General Metric Bolts 1098
HYDRAULIC CONNECTION SPECIFICATIONS 1099
Straight Thread O-ring Fitting 1099
Flare Fitting 1100
Tubelines And Hoses 1100
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 1101
Specifications 1101
CONVERSIONS 1103
Decimal And Millimeter Equivalent Chart 1103
U S To Metric Conversion Chart 1103
SERVICE TOOLS REQUIRED 1105
Remote Start Tools 1105
Hydraulic Tools 1106
Mainframe And Drive Tools 1109
Electrical Tools 1112
Engine Tools 1113
HVAC Tools 1118
ALPHABETICAL INDEX 1119

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