Bobcat S510 Skid-Steer Loader Service Manual 6990669 (06-19) – PDF DOWNLOAD

Description

Bobcat S510 Skid-Steer Loader Service Manual 6990669 (06-19) – PDF DOWNLOAD

FILE DETAILS:

Bobcat S510 Skid-Steer Loader Service Manual 6990669 (06-19) – PDF DOWNLOAD

Language : English
Pages : 1148
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S510 Skid-Steer Loader Service Manual 6990669 (06-19) – PDF DOWNLOAD

S/N ALNW11001 & Above
S/N B42S11001 & 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 6990669 (06-19) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
LOADER IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE LOADER 23
Procedure 23
LIFT ARM SUPPORT DEVICE 25
Description 25
Installing 26
Removing 27
OPERATOR CAB 29
Description 29
Cab Door Sensor 29
Raising 30
Lowering 31
Special Applications Kit 32
Special Applications Kit Inspection And Maintenance 32
Forestry Door And Window Kit 33
Forestry Door And Window Kit Inspection And Maintenance 33
TRANSPORTING THE LOADER ON A TRAILER 35
Loading And Unloading 35
Fastening 35
TOWING THE LOADER 37
Procedure 37
REMOTE START TOOL KIT- MEL1563 39
Remote Start Tool – MEL1563 39
Service Tool Harness Communicator – MEL1566 41
Remote Start Procedure 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 57
Maintenance Platform 57
Cleaning 57
Checking And Adding Coolant 59
Removing And Replacing Coolant 60
FUEL SYSTEM 63
Fuel Specifications 63
Biodiesel Blend Fuel 63
Filling The Fuel Tank 64
Fuel Filter 65
Removing Air From The Fuel System 67
ENGINE LUBRICATION SYSTEM 69
Checking And Adding Engine Oil 69
Engine Oil Chart 69
Removing And Replacing Oil And Filter 70
HYDRAULIC / HYDROSTATIC SYSTEM 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 79
FINAL DRIVE TRANSMISSION (CHAINCASE) 81
Checking And Adding Fluid 81
Removing And Replacing Fluid 81
BOB-TACH (HAND LEVER) 83
Inspection And Maintenance 83
BOB-TACH (POWER) 85
Inspection And Maintenance 85
LUBRICATING THE LOADER 87
Lubrication Locations 87
TIRE MAINTENANCE 91
Wheel Nuts 91
Rotating 91
Mounting 92
PIVOT PINS 93
Inspection And Maintenance 93
LOADER STORAGE AND RETURN TO SERVICE 95
Storage 95
Return To Service 95
STOPPING THE ENGINE AND LEAVING THE LOADER 97
Procedure 97
EMERGENCY EXIT 99
Rear Window Identification 99
Rear Window Removal (Latches) 99
Rear Window Removal (Rubber Cord) 99
External Access (Rear Window With Latches) 100
External Access (Rear Window With Rubber Cord) 100
Front Door 100
SEAT BELT 103
Inspection And Maintenance 103
HYDRAULIC SYSTEM 105
HYDRAULIC / HYDROSTATIC SCHEMATICS 109
HYDRAULIC SYSTEM INFORMATION 121
Glossary Of Hydraulic / Hydrostatic Symbols 121
Troubleshooting 125
CYLINDER (LIFT) 127
Testing 127
Removal And Installation 128
Parts Identification 131
Disassembly 132
Assembly 134
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) (B42S11009 & ABOVE) 149
Testing 149
Removal And Installation 150
Parts Identification 153
Disassembly 154
Assembly 156
CYLINDER (TILT) (B42S11009 & ABOVE) 161
Testing 161
Removal And Installation 162
Base End Pivot Pin Removal And Installation 163
Parts Identification 164
Disassembly 165
Assembly 167
CYLINDER (BOB-TACH) 171
Testing 171
Removal And Installation 172
Parts Identification 173
Disassembly 174
Assembly 176
MAIN RELIEF VALVE 179
Description 179
Testing 180
Adjusting 182
Removal And Installation 183
HYDRAULIC CONTROL VALVE (STANDARD) 185
Description 185
Removal And Installation 186
Mount Bracket Removal And Installation 189
Identification Chart 190
Lift Load Check Valve Removal And Installation 191
Load Check Valve Removal And Installation (Tilt And Auxiliary) 192
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 193
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 193
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 194
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 194
Port Relief Valve Removal And Installation 195
Plug Removal And Installation 197
Rubber Boot Removal And Installation 198
End Cap Block Removal And Installation 198
Lift Spool And Detent Removal And Installation 199
Tilt Spool Removal And Installation 207
Auxiliary Spool Removal And Installation 209
Auxiliary Solenoid Removal And Installation 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
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 217
Description 217
Removal And Installation 217
Actuator Removal And Installation (In Loader) 221
Actuator Removal And Installation (Out Of Loader) 223
Identification Chart 226
Mount Bracket Removal And Installation 227
Lift Load Check Valve Removal And Installation 227
Load Check Valve Removal And Installation (Tilt And Auxiliary) 228
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 229
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 229
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 230
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 230
Port Relief Valve Removal And Installation 231
Plug Removal And Installation 233
End Cap Block Removal And Installation 234
Lift Spool Removal And Installation 234
Lift Spool Disassembly And Assembly 236
Tilt Spool Removal And Installation 237
Auxiliary Spool Removal And Installation 239
Auxiliary Solenoid Removal And Installation 240
Solenoid Removal And Installation 241
Lock Valve Removal And Installation 242
Lift Arm Bypass Orifice Removal And Installation 244
Main Relief Valve Removal And Installation 244
Check Valve Removal And Installation 245
LIFT ARM BYPASS CONTROL VALVE 247
Description 247
Testing 247
Removal And Installation 248
Bracket Removal And Installation 249
Disassembly And Assembly 249
HYDRAULIC PUMP 251
Description 251
Pump Test At Quick Couplers 252
Direct Pump Test (Standard Section) 254
Direct Pump Test (Charge Section) 256
Removal And Installation 258
Hydraulic Pump Startup 260
Parts Identification 261
Disassembly And Assembly 262
HYDRAULIC / HYDROSTATIC FILTERS 263
Description 263
Housing Removal And Installation 263
HYDRAULIC FLUID RESERVOIR 265
Description 265
Removal And Installation 265
Hydraulic Fluid Screen 266
OIL COOLER 267
Removal And Installation 267
BUCKET POSITION VALVE 269
Description 269
Solenoid Removal And Installation 269
Solenoid Testing 271
Removal And Installation 271
Disassembly And Assembly 273
REAR AUXILIARY DIVERTER VALVE 275
Description 275
Solenoid Testing 275
Removal And Installation 276
Disassembly And Assembly 277
BOB-TACH (POWER) BLOCK (S/N ALNW11001-12252) 283
Description 283
Removal And Installation 283
Disassembly And Assembly 285
BOB-TACH (POWER) BLOCK (S/N ALNW12253 & ABOVE) 293
Description 293
Testing Relief Valve 294
Removal And Installation 296
Disassembly And Assembly 298
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 303
Description 303
Removal And Installation 304
Disassembly And Assembly (FFI/FI) 304
Disassembly And Assembly (FFH/FH) 306
AUTOMATIC RIDE CONTROL 309
Description 309
Removal and Installation 310
Checking The Pressure In The Accumulator 313
Adding Nitrogen To The Accumulator 315
HYDROSTATIC SYSTEM 317
HYDROSTATIC SYSTEM INFORMATION 319
Description 319
Troubleshooting 320
HYDROSTATIC DRIVE MOTOR 321
Description 321
Removal And Installation 321
Parts Identification 324
Disassembly And Assembly 325
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 331
Description 331
Removal And Installation (Left Side) 332
Removal And Installation (Right Side) 335
Parts Identification 338
Disassembly 339
Assembly 352
HYDROSTATIC MOTOR CARRIER 367
Description 367
Shaft Seal Removal And Installation 368
Removal And Installation 370
Parts Identification 372
Disassembly 373
Assembly 375
HYDROSTATIC MOTOR CARRIER (TWO-SPEED) 379
Description 379
Shaft Seal Removal And Installation 380
Removal And Installation 382
Parts Identification 384
Disassembly 385
Assembly 387
CHARGE PRESSURE 391
Description 391
Testing 392
Adjusting 394
Sender Removal And Installation (Earlier Models) 396
Sender Removal And Installation (Later Models) 396
HYDROSTATIC PUMP 397
Description 397
Removal And Installation 398
Hydrostatic Pump Startup 399
Replenishing / High Pressure Relief Valve Removal And Installation 400
Parts Identification (Left Half) 401
Parts Identification (Right Half) 402
Disassembly 403
Assembly 410
HYDROSTATIC PUMP (SJC) 417
Description 417
Hydraulic Controller Removal And Installation 418
Removal And Installation 420
Hydrostatic Pump Startup 422
Parts Identification 423
High Pressure Relief And Bypass Valve 424
Charge Relief Valve 425
Disassembly And Assembly 426
Mechanical NEUTRAL Adjustment 439
Hydraulic Controller NEUTRAL Adjustment 442
DRIVE BELT 445
Belt Adjustment 445
Stop Adjustment 445
Belt Replacement 446
Tensioner Removal And Installation (Earlier Models) 448
Tensioner Disassembly And Assembly 448
Tensioner Pulley Removal And Installation (Later Models) 449
Tensioner Pulley Disassembly And Assembly 449
TWO-SPEED 451
Valve Block Removal And Installation 451
Valve Block Disassembly And Assembly 452
DRAIN MANIFOLD 453
Description 453
Drain Manifold Removal And Installation 453
DRIVE SYSTEM 455
BRAKE 457
Description 457
Disc Removal And Installation 457
DRIVE COMPONENTS 459
Description 459
Axle Seal Removal And Installation 460
Axle, Sprocket And Bearings Removal And Installation 462
Chain Removal And Installation 467
CHAINCASE 469
Description 469
Front Cover Removal And Installation 469
Center Cover Removal And Installation 470
Rear Cover Removal And Installation 471
MAINFRAME 473
SEAT BAR 477
Description 477
Removal And Installation 477
Disassembly And Assembly 478
Compression Spring Disassembly And Assembly 479
OPERATOR CAB 481
Gas Spring Removal And Installation 481
Gas Spring Bracket Disassembly And Assembly 482
Removal And Installation 482
OPERATOR SEAT 485
Removal And Installation 485
Seat Belt Removal And Installation (Retractable) 485
Seat Belt And Bracket Removal And Installation (Standard) 486
Seat Belt Bracket Removal And Installation 486
OPERATOR SEAT (SUSPENSION) 487
Removal And Installation 487
Slide Rail Removal And Installation 487
Seat Belt Removal And Installation 488
Lower Cushion Removal 488
Lower Cushion Installation 489
Back Cushion Removal And Installation 489
Shock Removal And Installation 490
3-Point Seat Belt Removal And Installation 490
BOB-TACH (HAND LEVER) 493
Description 493
Removal And Installation 493
Lever And Wedge Disassembly And Assembly 495
Pivot Pin Bushing And Seal Removal And Installation 498
BOB-TACH (POWER) 499
Description 499
Removal And Installation 499
Lever And Wedge Disassembly And Assembly 502
Pivot Pin Bushing And Seal Removal And Installation 504
LIFT ARMS 505
Removal And Installation 505
REAR GRILLE 507
Removing 507
Installing 507
Shield Removal And Installation 508
REAR DOOR (TAILGATE) 509
Removal And Installation 509
Striker Removal And Installation 510
Striker Disassembly And Assembly 510
Striker Adjusting 511
Latch Removal And Installation 512
FUEL TANK 513
Removal And Installation 513
Fuel Level Sender Removal And Installation 515
Fuel Fill Screen Removal And Installation 515
CONTROL PEDALS AND LINKAGES 517
Description 517
Pedal Removal And Installation 517
Linkage Removal And Installation 518
Pedal (Adjusting) 519
Floor Pan Removal And Installation 520
CONTROL PEDALS AND LINKAGES (ACS) 521
Description 521
Pedal Removal And Installation 521
Linkage Removal And Installation 522
Pedal (Adjusting) 522
Floor Pan Removal And Installation 523
CONTROL PANEL 525
Description 525
Removal And Installation 526
Disassembly And Assembly 528
Linkage Removal And Installation 532
Pintle Arm Disassembly And Assembly 535
Linkage NEUTRAL (Adjusting) 536
Linkage Travel (Adjusting) 540
Shock Removal And Installation 544
CONTROL PANEL (SJC) 545
Description 545
Removal And Installation 545
CONTROL HANDLE / LEVER 547
Description 547
Lever Removal And Installation 547
Boot Removal And Installation 548
CONTROL HANDLE / LEVER (ACS) 549
Description 549
Handle Sensor Removal And Installation 549
Handle Removal And Installation 552
Handle Disassembly And Assembly 553
Lever Removal And Installation 553
Boot Removal And Installation 554
CONTROL HANDLE / LEVER (SJC) 555
Description 555
Joystick Testing 555
Joystick Removal And Installation 556
ACCESS PANEL (INSIDE) 557
Removal And Installation (Left) 557
Removal And Installation (Right) 557
ACCESS PANEL (INSIDE) (SJC) 559
Removal And Installation (Left) 559
Removal And Installation (Right) 559
WINDOW (REAR) 561
Rear Window Identification 561
Rear Window Removal (Latches) 561
Rear Window Removal (Rubber Cord) 561
Disassembly And Assembly 562
External Access (Rear Window With Latches) 563
External Access (Rear Window With Rubber Cord) 563
WINDOW (TOP) 565
Removal And Installation 565
WINDOW (SIDE) 567
Removal And Installation 567
CAB DOOR 569
Description 569
Removal And Installation 569
Disassembly And Assembly 570
Aligning 571
Adjusting 572
Checking Operation 572
ARMREST 573
Description 573
Removal And Installation 574
Disassembly And Assembly 575
LEFT SIDE LOWER PANEL 577
Removal And Installation 577
Disassembly And Assembly 579
RIGHT SIDE LOWER PANEL 581
Removal And Installation 581
Disassembly And Assembly 582
HEADLINER 585
Removal And Installation 585
FAN DUCT PANELS 587
Removal And Installation 587
ELECTRICAL SYSTEM 589
ELECTRICAL SCHEMATICS 595
ELECTRICAL SYSTEM INFORMATION 767
Glossary Of Electrical Symbols 767
Standard Cab Harness Connectors 770
Deluxe Cab Harness Connectors 771
Mainframe Harness Connectors – Manual Controls 772
Mainframe Harness Connectors – SJC 773
Engine Harness Connectors 774
Description 775
Troubleshooting 776
Fuse And Relay Location / Identification 777
Solenoid Testing 781
BATTERY 783
Removal And Installation 783
Servicing 784
Using A Booster Battery (Jump Starting) 785
ALTERNATOR 787
Belt Adjustment 787
Belt Replacement 788
Charging System Inspection 789
Alternator Voltage Testing 790
Low Voltage Testing 790
High Voltage Testing 791
Removal And Installation 792
Parts Identification 794
STARTER 795
Testing 795
Removal And Installation 795
Parts Identification 796
INSTRUMENT PANELS 797
Left Panel 797
Display Screen 799
Right Panel (Standard Key Panel) 800
Right Panel (Keyless Start Panel) 801
Right Panel (Deluxe Instrumentation Panel) 802
Left Switch Panel 804
Right Switch Panel 804
Left Side Lower Panel 805
Right Side Lower Panel 805
Left Panel Removal And Installation 806
Right Panel (Standard Key Panel) Removal And Installation 806
Right Panel (Keyless Start Panel) Removal And Installation 807
Right Panel (Deluxe Instrumentation Panel) Removal And Installation 807
Key Switch Disassembly And Assembly 808
Alarm Disassembly And Assembly 808
Left Switch Panel Removal And Installation 809
Right Switch Panel Removal And Installation 809
LIGHTS 811
Front Removal And Installation 811
Rear Removal And Installation 812
Cab Light Removal And Installation (Earlier Models) 812
Cab Light Removal And Installation (Later Models) 813
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) 815
Description 815
Connector Identification 816
Removal And Installation 822
BOBCAT CONTROLLER (ACS) 823
Description 823
Connector And Wire Identification 824
Removal And Installation 825
BOBCAT CONTROLLER (SJC) (DRIVE) 827
Description 827
Connector Identification 828
Removal And Installation 830
ENGINE CONTROL UNIT (ECU) 831
Description 831
Cleaning 832
Removal And Installation 833
DIAGNOSTIC SERVICE CODES 835
Viewing Service Codes 835
Service Codes List 836
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 845
Description 845
Inspecting The BICS™ (Engine STOPPED – Key ON) 846
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 846
Inspecting The Seat Bar Sensor (Engine RUNNING) 846
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 846
Inspecting The Lift Arm Bypass Control 846
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) 846
Troubleshooting 847
SEAT BAR SENSOR 849
Description 849
Troubleshooting 849
Testing 850
Removal 851
Installation 853
Bobcat Interlock Control System (BICS™) Circuit Test 854
TRACTION LOCK 857
Description 857
Troubleshooting 858
Inspecting 859
CONTROL SYSTEM (ACS) 861
Description 861
Troubleshooting 862
Handle Sensor Connector Disassembly And Assembly 863
Switch Handle Removal 864
Switch Handle Installation 866
Actuator Connector Disassembly And Assembly 869
Handle Lock Solenoid Removal And Installation 870
Handle Lock Solenoid Disassembly And Assembly 870
Foot Sensor Removal And Installation 871
Foot Sensor Disassembly And Assembly 872
Foot Sensor Lock Solenoid Removal And Installation 872
ELECTRICAL / HYDRAULIC CONTROLS 873
Identification Chart 873
Description 874
Identification Chart ACD Group 0 875
Identification Chart ACD Group 1 876
Identification Chart ACD Group 2 877
Identification Chart ACD Group 3 878
ELECTRICAL / HYDRAULIC CONTROLS (ACS) 879
Identification Chart 879
Description 880
Identification Chart ACD Group 0 881
Identification Chart ACD Group 1 882
Identification Chart ACD Group 2 883
Identification Chart ACD Group 3 884
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 885
Identification Chart 885
Description 886
Identification Chart ACD Group 0 887
Identification Chart ACD Group 1 888
Identification Chart ACD Group 2 889
Identification Chart ACD Group 3 890
SERVICE PC (LAPTOP COMPUTER) 891
Connecting Remote Start Tool 891
Connecting Remote Start Tool (Service Tool) 891
CALIBRATION 893
Description 893
Actuator Testing 893
Lift And Tilt Calibration (SJC) 896
Hydrostatic Pump Calibration (SJC) 898
Lift And Tilt Calibration (ACS) 903
STEERING DRIFT COMPENSATION (OPERATOR MODE) 905
Description 905
Operation 905
STEERING DRIFT COMPENSATION (SERVICE MODE) 907
Description 907
Operation 907
CONTROL PANEL SETUP 909
Right Panel Setup (Deluxe Instrumentation Panel) 909
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 913
Password Description 913
Changing The Owner Password 913
Changing The User Passwords 914
Password Lockout Feature 914
PASSWORD SETUP (KEYLESS START PANEL) 915
Password Description 915
Changing The Owner Password 915
Password Lockout Feature 915
MAINTENANCE CLOCK 917
Description 917
Setup 918
Reset 921
BACK-UP ALARM SYSTEM 923
Description 923
Inspecting 923
Adjusting Switch Position 924
Troubleshooting (Standard And ACS) 925
Troubleshooting (Joystick) 926
Alarm Removal And Installation 927
Switch Removal And Installation 927
FRONT HORN 929
Removal And Installation 929
Troubleshooting 930
Troubleshooting (Joystick) 931
ENGINE SPEED CONTROL (HAND) 933
Removal And Installation 933
ENGINE SPEED CONTROL (FOOT) 935
Removal And Installation 935
Disassembly And Assembly 936
Foot Throttle Calibration 938
CAMSHAFT AND CRANKSHAFT POSITION SENSOR 941
Removal And Installation 941
ENGINE SERVICE 943
ENGINE INFORMATION 947
Description 947
Specifications 948
Sensor Location 950
Torque Values 956
Troubleshooting 958
Engine Removal And Installation 960
Engine Mount Replacement 969
Compression – Testing 971
Injector Signal – Testing 973
Injector Signal – Testing (In-Line) 975
DIESEL OXIDATION CATALYST (DOC) 977
Removal And Installation 977
AIR CLEANER 979
Housing Removal And Installation 979
ENGINE COOLING SYSTEM (EARLIER MODELS) 981
Radiator / Oil Cooler Removal And Installation 981
Hydraulic Fan Description 984
Fan Duct Removal And Installation 984
Hydraulic Fan Motor Assembly Removal And Installation 985
Hydraulic Fan Motor Removal And Installation 986
Hydraulic Fan Motor Disassembly And Assembly 988
Blower Housing Removal And Installation 989
Water Pump Removal And Installation 990
Thermostat Housing Removal And Installation 991
Testing The Thermostat 992
ENGINE COOLING SYSTEM (LATER MODELS) 993
Radiator / Oil Cooler Removal And Installation 993
Hydraulic Fan Description 996
Reversible Hydraulic Fan Description 996
Fan Duct Removal And Installation 996
Hydraulic Fan Motor Assembly Removal And Installation 997
Hydraulic Fan Motor Removal And Installation 998
Hydraulic Fan Motor Disassembly And Assembly 1000
Hydraulic Fan Motor Assembly Removal And Installation 1008
Blower Housing Removal And Installation 1008
Water Pump Removal And Installation 1009
Thermostat Housing Removal And Installation 1010
Testing The Thermostat 1011
LUBRICATION SYSTEM 1013
Description 1013
Oil Pan Removal And Installation 1014
Oil Pump Removal And Installation 1015
Oil Pump Relief Valve Description 1016
Oil Pump Relief Valve Removal And Installation 1016
Oil Cooler Removal And Installation 1017
Oil Filter Head Removal And Installation 1018
Oil Cooler Bypass Description 1019
Oil Cooler Bypass Removal And Installation 1019
FUEL SYSTEM 1021
Description 1021
Transfer Pump / High Pressure Pump Removal And Installation 1022
Fuel Temperature Sensor Removal And Installation 1024
Fuel Cooler Removal And Installation 1025
Fuel Bypass Valve Removal And Installation 1025
Fuel Recirculation Valve Removal And Installation 1026
Fuel Rail Assembly Removal And Installation 1027
Fuel Injector Removal And Installation 1028
Injector Coding 1030
Removing Air From The Fuel System 1032
CYLINDER HEAD 1035
Glow Plugs Testing 1035
Glow Plug Removal And Installation 1036
Valve Clearance Adjustment 1037
Cylinder Head Removal And Installation 1039
Cylinder Head Disassembly And Assembly 1043
Cylinder Head Inspection 1044
Cylinder Head Top Clearance 1045
Valve Step Height 1046
Valve Stem Height 1046
Valve Guide 1047
Valve 1047
Valve Spring 1048
Rocker Arm Shaft Disassembly And Assembly 1049
Rocker Arm Shaft Inspection 1050
Push Rod Inspection 1050
CRANKSHAFT AND PISTONS 1051
Piston And Connecting Rod Removal And Installation 1051
Piston And Connecting Rod Inspection 1052
Crankshaft Removal And Installation 1054
Cylinder Block Inspection 1057
Crankshaft Inspection 1059
Connecting Rod Inspection 1059
Engine Component Class 1060
CAMSHAFT 1063
Removal And Installation 1063
Inspecting 1064
GEAR CASE 1067
Gear Case Cover Removal And Installation 1067
Gear Backlash 1068
Gear Timing 1069
Idle Gear Removal And Installation 1070
Idle Gear Inspection 1070
TURBOCHARGER 1071
Description 1071
Removal And Installation 1071
Inspection 1073
FLYWHEEL AND HOUSING 1075
Flywheel Removal And Installation 1075
Ring Gear Removal And Installation 1076
Housing Removal And Installation 1076
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 1077
Description 1077
Removal And Installation 1078
Disassembly And Assembly 1082
HEATING AND VENTILATION 1085
REGULAR MAINTENANCE 1087
Filters 1087
Heater Coil 1088
TROUBLESHOOTING 1091
Blower Motor Does Not Operate 1091
Blower Motor Operates Normally, But Air Flow Is Insufficient 1091
Troubleshooting Tree 1092
Electrical System 1094
Engine Coolant Bypassing The Heater Valve 1097
Heater Valve Not Opening Or Closing 1098
HEATER UNIT 1099
Removal And Installation 1099
HEATER COIL 1101
Removal And Installation 1101
BLOWER FAN 1103
Removal And Installation 1103
Disassembly And Assembly 1103
HEATER VALVE 1107
Removal And Installation 1107
EVAPORATOR / HEATER COVER 1109
Removing 1109
Installing 1109
SPECIFICATIONS 1111
(S510) LOADER SPECIFICATIONS 1113
Machine Dimensions 1113
Performance 1114
Engine 1114
Drive System 1115
Controls 1115
Hydraulic System 1116
Electrical System 1117
Capacities 1117
Tires 1118
TECHINCAL SERVICE GUIDE SPECIFICATIONS 1119
Engine 1119
Engine Torques 1119
Cooling System 1119
Loader Torques 1120
Hydraulic / Hydrostatic System 1120
Fuel Consumption 1120
TORQUE SPECIFICATIONS FOR BOLTS 1121
Torque For General SAE Bolts 1121
Torque For General Metric Bolts 1122
HYDRAULIC CONNECTION SPECIFICATIONS 1123
Straight Thread O-ring Fitting 1123
Flare Fitting 1124
Tubelines And Hoses 1124
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 1125
Specifications 1125
CONVERSIONS 1127
Decimal And Millimeter Equivalent Chart 1127
U S To Metric Conversion Chart 1127
SERVICE TOOLS REQUIRED 1129
Remote Start Tools 1129
Hydraulic Tools 1130
Mainframe And Drive Tools 1133
Electrical Tools 1136
Engine Tools 1137
HVAC Tools 1142
ALPHABETICAL INDEX 1143

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Questions? Email us: [email protected]

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V