Bobcat S510 Skid-Steer Loader Service Manual SN B4RE11001 & Above – PDF DOWNLOAD

Description

Bobcat S510 Skid-Steer Loader Service Manual SN B4RE11001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat S510 Skid-Steer Loader Service Manual SN B4RE11001 & Above – PDF DOWNLOAD

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

DESCRIPTION:

Bobcat S510 Skid-Steer Loader Service Manual SN B4RE11001 & Above – PDF DOWNLOAD

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 SN B4RE11001 & Above – 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
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 60
Removing And Replacing Coolant 61
FUEL SYSTEM 63
Fuel Specifications 63
Biodiesel Blend Fuel 63
Filling The Fuel Tank 64
Removing Water From Main Fuel Filter 65
Replacing Fuel Pre-Filter 66
Replacing Main Fuel Filter 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 78
FINAL DRIVE TRANSMISSION (CHAINCASE) 79
Checking And Adding Fluid 79
Removing And Replacing Fluid 79
BOB-TACH (HAND LEVER) 81
Inspection And Maintenance 81
BOB-TACH (POWER) 83
Inspection And Maintenance 83
LUBRICATING THE LOADER 85
Lubrication Locations 85
TIRE MAINTENANCE 89
Wheel Nuts 89
Rotating 89
Mounting 90
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 115
Glossary Of Hydraulic / Hydrostatic Symbols 115
Troubleshooting 119
CYLINDER (LIFT) 121
Testing 121
Removal And Installation 122
Parts Identification 125
Disassembly 126
Assembly 128
CYLINDER (TILT) 133
Testing 133
Removal And Installation 134
Base End Pivot Pin Removal And Installation 135
Parts Identification 136
Disassembly 137
Assembly 139
CYLINDER (BOB-TACH) 143
Testing 143
Removal And Installation 144
Parts Identification 145
Disassembly 146
Assembly 148
MAIN RELIEF VALVE 151
Description 151
Testing 152
Adjusting 154
Removal And Installation 155
HYDRAULIC CONTROL VALVE (STANDARD) 157
Description 157
Removal And Installation 158
Mount Bracket Removal And Installation 161
Identification Chart 162
Lift Load Check Valve Removal And Installation 163
Load Check Valve Removal And Installation (Tilt And Auxiliary) 164
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 165
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 165
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 166
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 166
Port Relief Valve Removal And Installation 167
Plug Removal And Installation 169
Rubber Boot Removal And Installation 170
End Cap Block Removal And Installation 170
Lift Spool And Detent Removal And Installation 171
Tilt Spool Removal And Installation 179
Auxiliary Spool Removal And Installation 181
Auxiliary Solenoid Removal And Installation 182
Solenoid Removal And Installation 183
Lock Valve Removal And Installation 184
Lift Arm Bypass Orifice Removal And Installation 186
Main Relief Valve Removal And Installation 186
Check Valve Removal And Installation 187
HYDRAULIC CONTROL VALVE (SJC) 189
Description 189
Removal And Installation 189
Mount Bracket Removal And Installation 192
Actuator Removal And Installation (In Loader) 193
Actuator Removal And Installation (Out Of Loader) 195
Identification Chart 198
Mount Bracket Removal And Installation 199
Lift Load Check Valve Removal And Installation 199
Load Check Valve Removal And Installation (Tilt And Auxiliary) 200
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 201
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 201
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 202
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 202
Port Relief Valve Removal And Installation 203
Plug Removal And Installation 205
End Cap Block Removal And Installation 206
Lift Spool Removal And Installation 206
Lift Spool Disassembly And Assembly 208
Tilt Spool Removal And Installation 209
Auxiliary Spool Removal And Installation 211
Auxiliary Solenoid Removal And Installation 212
Solenoid Removal And Installation 213
Lock Valve Removal And Installation 214
Lift Arm Bypass Orifice Removal And Installation 216
Main Relief Valve Removal And Installation 216
Check Valve Removal And Installation 217
LIFT ARM BYPASS CONTROL VALVE 219
Description 219
Testing 219
Removal And Installation 220
Bracket Removal And Installation 221
Disassembly And Assembly 221
HYDRAULIC PUMP 223
Description 223
Pump Test At Quick Couplers 224
Direct Pump Test (Standard Section) 226
Direct Pump Test (Charge Section) 228
Removal And Installation 230
Hydraulic Pump Startup 232
Parts Identification 233
Disassembly And Assembly 234
HYDRAULIC PUMP (HIGH FLOW) 235
Description 235
Pump Test At Quick Couplers 236
Direct Pump Test (Standard Section) 238
Direct Pump Test (Charge Section) 239
Direct Pump Test (High Flow Section) 241
High Flow Relief Valve Adjustment 243
High Flow Relief Valve Removal And Installation 245
Solenoid Removal And Installation 246
Removal And Installation 247
Hydraulic Pump Startup 249
Parts Identification 250
Disassembly And Assembly 251
HYDRAULIC / HYDROSTATIC FILTERS 253
Description 253
Housing Removal And Installation 253
HYDRAULIC FLUID RESERVOIR 255
Description 255
Removal And Installation 255
Hydraulic Fluid Screen 256
OIL COOLER 257
Removal And Installation 257
BUCKET POSITION VALVE 259
Description 259
Solenoid Testing 259
Removal And Installation 259
Disassembly And Assembly 261
REAR AUXILIARY DIVERTER VALVE 263
Description 263
Solenoid Testing 263
Removal And Installation 264
Disassembly And Assembly 265
BOB-TACH (POWER) BLOCK 271
Description 271
Testing Relief Valve 272
Removal And Installation 274
Disassembly And Assembly 276
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 281
Description 281
Removal And Installation 282
Disassembly And Assembly (FFI/FI) 282
Disassembly And Assembly (FFH/FH) 284
AUTOMATIC RIDE CONTROL 287
Description 287
Removal And Installation 288
Checking The Pressure In The Accumulator 290
Adding Nitrogen To The Accumulator 292
HYDROSTATIC SYSTEM 295
HYDROSTATIC SYSTEM INFORMATION 297
Description 297
Troubleshooting 298
HYDROSTATIC DRIVE MOTOR 299
Description 299
Removal And Installation 299
Parts Identification 302
Disassembly And Assembly 303
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 309
Description 309
Removal And Installation (Left Side) 310
Removal And Installation (Right Side) 313
Parts Identification 316
Disassembly 317
Assembly 330
HYDROSTATIC MOTOR CARRIER 345
Description 345
Shaft Seal Removal And Installation 346
Removal And Installation 348
Parts Identification 350
Disassembly 351
Assembly 353
HYDROSTATIC MOTOR CARRIER (TWO-SPEED) 357
Description 357
Shaft Seal Removal And Installation 358
Removal And Installation 360
Parts Identification 362
Disassembly 363
Assembly 365
CHARGE PRESSURE 369
Description 369
Testing 370
Adjusting 372
Sender Removal And Installation 374
HYDROSTATIC PUMP 375
Description 375
Removal And Installation 376
Hydrostatic Pump Startup 377
Replenishing / High Pressure Relief Valve Removal And Installation 378
Parts Identification (Left Half) 379
Parts Identification (Right Half) 380
Disassembly 381
Assembly 388
HYDROSTATIC PUMP (SJC) 395
Description 395
Port Locations And Gauge Installation 396
Removal And Installation 397
Hydrostatic Pump Startup 399
Parts Identification 400
High Pressure Relief And Bypass Valve 403
Charge Pressure Relief Valve 404
Disassembly And Assembly 405
Mechanical Neutral Adjustment 417
Hydraulic Controller Neutral Adjustment 419
DRIVE BELT 421
Belt Adjustment 421
Stop Adjustment 421
Belt Replacement 422
Tensioner Pulley Removal And Installation 424
Tensioner Pulley Disassembly And Assembly 424
TWO-SPEED 427
Valve Block Removal And Installation 427
Valve Block Disassembly And Assembly 428
DRAIN MANIFOLD 429
Description 429
Drain Manifold Removal And Installation 429
DRIVE SYSTEM 431
BRAKE 433
Description 433
Disc Removal And Installation 433
DRIVE COMPONENTS 435
Description 435
Axle Seal Removal And Installation 436
Axle, Sprocket And Bearings Removal And Installation 438
Chain Removal And Installation 443
CHAINCASE 445
Description 445
Front Cover Removal And Installation 445
Center Cover Removal And Installation 446
Rear Cover Removal And Installation 447
MAINFRAME 449
SEAT BAR 453
Description 453
Removal And Installation 453
Disassembly And Assembly 454
Compression Spring Disassembly And Assembly 455
OPERATOR CAB 457
Gas Spring Removal And Installation 457
Gas Spring Bracket Disassembly And Assembly 458
Removal And Installation 458
OPERATOR SEAT 461
Removal And Installation 461
Seat Belt Removal And Installation (Retractable) 461
Seat Belt And Bracket Removal And Installation (Standard) 462
Seat Belt Bracket Removal And Installation 462
OPERATOR SEAT (SUSPENSION) 463
Removal And Installation 463
Slide Rail Removal And Installation 463
Seat Belt Removal And Installation 464
Lower Cushion Removal 464
Lower Cushion Installation 465
Back Cushion Removal And Installation 465
Shock Removal And Installation 466
3-Point Seat Belt Removal And Installation 466
BOB-TACH (HAND LEVER) 469
Description 469
Removal And Installation 469
Lever And Wedge Disassembly And Assembly 472
Pivot Pin Bushing And Seal Removal And Installation 474
BOB-TACH (POWER) 475
Description 475
Removal And Installation 475
Lever And Wedge Disassembly And Assembly 478
Pivot Pin Bushing And Seal Removal And Installation 480
LIFT ARMS 481
Removal And Installation 481
REAR GRILLE 483
Removing 483
Installing 483
Shield Removal And Installation 484
REAR DOOR (TAILGATE) 485
Removal And Installation 485
Striker Removal And Installation 486
Striker Disassembly And Assembly 486
Striker Adjusting 487
Latch Removal And Installation 488
FUEL TANK 489
Removal And Installation 489
Fuel Level Sender Removal And Installation 491
CONTROL PEDALS AND LINKAGES 493
Description 493
Pedal Removal And Installation 493
Linkage Removal And Installation 494
Pedal (Adjusting) 495
Floor Pan Removal And Installation 496
CONTROL PANEL 497
Description 497
Removal And Installation 498
Disassembly And Assembly 500
Linkage Removal And Installation 502
Pintle Arm Disassembly And Assembly 505
Linkage Neutral (Adjusting) 506
Linkage Travel (Adjusting) 510
Shock Removal And Installation 514
CONTROL PANEL (SJC) 515
Description 515
Removal And Installation 515
CONTROL HANDLE / LEVER 517
Description 517
Lever Removal And Installation 517
Boot Removal And Installation 518
CONTROL HANDLE / LEVER (SJC) 519
Description 519
Joystick Testing 519
Joystick Removal And Installation 520
ACCESS PANEL (INSIDE) 521
Removal And Installation (Left) 521
Removal And Installation (Right) 521
ACCESS PANEL (INSIDE) (SJC) 523
Removal And Installation (Left) 523
Removal And Installation (Right) 523
WINDOW (REAR) 525
Rear Window Identification 525
Rear Window Removal (Latches) 525
Rear Window Removal (Rubber Cord) 525
External Access (Rear Window With Latches) 526
External Access (Rear Window With Rubber Cord) 526
Disassembly And Assembly (Latches) 527
WINDOW (TOP) 529
Removal And Installation 529
WINDOW (SIDE) 531
Removal And Installation 531
CAB DOOR 533
Description 533
Removal And Installation 533
Disassembly And Assembly 534
Aligning 535
Adjusting 536
Checking Operation 536
ARMREST 537
Description 537
Removal And Installation 538
Disassembly And Assembly 539
LEFT SIDE LOWER PANEL 541
Removal And Installation 541
Disassembly And Assembly 544
RIGHT SIDE LOWER PANEL 545
Removal And Installation 545
Disassembly And Assembly 547
HEADLINER 549
Removal And Installation 549
FAN DUCT PANELS 551
Removal And Installation 551
ELECTRICAL SYSTEM 553
ELECTRICAL SCHEMATICS 559
ELECTRICAL SYSTEM INFORMATION 601
Glossary Of Electrical Symbols 601
Standard Cab Harness Connectors 604
Deluxe Cab Harness Connectors 605
Mainframe Harness Connectors – Manual Controls 606
Mainframe Harness Connectors – SJC 607
Engine Harness Connectors 608
Description 609
Troubleshooting 610
Fuse And Relay Location / Identification 611
Solenoid Testing 614
BATTERY 615
Removal And Installation 615
Battery Maintenance 616
Maintaining Battery Charge Level 616
Battery Service During Machine Storage 616
Battery Testing 617
Battery Charging 617
Using A Booster Battery (Jump Starting) 618
ALTERNATOR 619
Belt Adjustment 619
AIR CONDITIONING BELT 620
Belt Adjustment 620
Belt Replacement 620
Charging System Inspection 621
Alternator Voltage Testing 622
Low Voltage Testing 622
High Voltage Testing 623
Removal And Installation 624
Parts Identification 626
STARTER 627
Testing 627
Removal And Installation 627
Parts Identification 628
INSTRUMENT PANELS 629
Left Panel 629
Display Screen 631
Right Panel (Standard Key Panel) 632
Right Panel (Keyless Start Panel) 633
Right Panel (Deluxe Instrumentation Panel) 634
Left Switch Panel 636
Right Switch Panel 636
Left Side Lower Panel 637
Right Side Lower Panel 637
Left Panel Removal And Installation 638
Right Panel (Standard Key Panel) Removal And Installation 638
Right Panel (Keyless Start Panel) Removal And Installation 639
Right Panel (Deluxe Instrumentation Panel) Removal And Installation 639
Key Switch Disassembly And Assembly 640
Alarm Disassembly And Assembly 640
Left Switch Panel Removal And Installation 641
Right Switch Panel Removal And Installation 641
LIGHTS 643
Front Removal And Installation 643
Rear Removal And Installation 644
Cab Light Removal And Installation 644
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) 645
Description 645
Connector Identification 646
Removal And Installation 652
BOBCAT CONTROLLER (SJC) (DRIVE) 653
Description 653
Connector Identification 654
Removal And Installation 656
ENGINE CONTROL UNIT (ECU) 657
Description 657
Cleaning 658
Removal And Installation 659
DIAGNOSTIC SERVICE CODES 661
Viewing Service Codes 661
Service Codes List 662
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 677
Description 677
Inspecting The BICS™ (Engine STOPPED – Key ON) 678
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 678
Inspecting The Seat Bar Sensor (Engine RUNNING) 678
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 678
Inspecting The Lift Arm Bypass Control 678
Inspecting Deactivation Of Lift And Tilt Functions (SJC) 678
Troubleshooting 679
SEAT BAR SENSOR 681
Description 681
Troubleshooting 681
Testing 682
Removal 683
Installation 685
Bobcat Interlock Control System (BICS™) Circuit Test 686
TRACTION LOCK 689
Description 689
Troubleshooting 690
Inspecting 691
ELECTRICAL / HYDRAULIC CONTROLS 693
Identification Chart 693
Description 694
Identification Chart ACD Group 0 695
Identification Chart ACD Group 1 696
Identification Chart ACD Group 2 697
Identification Chart ACD Group 3 698
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 699
Identification Chart 699
Description 700
Identification Chart ACD Group 0 701
Identification Chart ACD Group 1 702
Identification Chart ACD Group 2 703
Identification Chart ACD Group 3 704
SERVICE PC (LAPTOP COMPUTER) 705
Connecting Remote Start Tool 705
Connecting Remote Start Tool (Service Tool) 705
CALIBRATION 707
Description 707
Actuator Testing 707
Lift And Tilt Calibration (SJC) 710
Hydrostatic Pump Calibration (SJC) 712
Lift And Tilt Calibration (ACS) 717
STEERING DRIFT COMPENSATION (OPERATOR MODE) 719
Description 719
Operation 719
STEERING DRIFT COMPENSATION (SERVICE MODE) 721
Description 721
Operation 721
CONTROL PANEL SETUP 723
Right Panel Setup (Deluxe Instrumentation Panel) 723
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 727
Password Description 727
Changing The Owner Password 727
Changing The User Passwords 728
Password Lockout Feature 728
PASSWORD SETUP (KEYLESS START PANEL) 729
Password Description 729
Changing The Owner Password 729
Password Lockout Feature 729
MAINTENANCE CLOCK 731
Description 731
Setup 732
Reset 735
BACK-UP ALARM SYSTEM 737
Description 737
Inspecting 737
Adjusting Switch Position 738
Troubleshooting (Standard) 739
Troubleshooting (Joystick) 740
Alarm Removal And Installation 741
Switch Removal And Installation 741
FRONT HORN 743
Removal And Installation 743
Troubleshooting 744
Troubleshooting (Joystick) 745
ENGINE SPEED CONTROL (HAND) 747
Removal And Installation 747
ENGINE SPEED CONTROL (FOOT) 749
Removal And Installation 749
Disassembly And Assembly 750
Foot Throttle Calibration 752
CAMSHAFT AND CRANKSHAFT POSITION SENSOR 755
Removal And Installation 755
MACHINE IQ 757
Description 757
Removal And Installation 757
Procedure 758
ENGINE SERVICE 759
ENGINE INFORMATION 763
Description 763
Specifications 764
Sensor Location 766
Torque Values 771
Troubleshooting 773
Engine Removal And Installation 775
Engine Mount Replacement 783
Compression – Testing 785
Injector Signal – Testing 787
Injector Signal – Testing (In-Line) 789
Oil Pressure Testing (At Oil Sensor On Block) 791
Oil Pressure Testing (At Turbocharger Oil Inlet) 793
DIESEL OXIDATION CATALYST (DOC) 795
Removal And Installation 795
AIR CLEANER 797
Housing Removal And Installation 797
ENGINE COOLING SYSTEM 799
Radiator / Oil Cooler Removal And Installation 799
Hydraulic Fan Description 802
Reversible Hydraulic Fan Description 802
Fan Duct Removal And Installation 802
Hydraulic Fan Motor Assembly Removal And Installation 803
Hydraulic Fan Motor Removal And Installation 804
Hydraulic Fan Motor Disassembly And Assembly 806
Blower Housing Removal And Installation 814
Water Pump Removal And Installation 815
Thermostat Housing Removal And Installation 816
Testing The Thermostat 817
LUBRICATION SYSTEM 819
Description 819
Oil Pan Removal And Installation 820
Oil Pump Removal And Installation 821
Oil Pump Relief Valve Description 822
Oil Pump Relief Valve Removal And Installation 822
Oil Cooler Removal And Installation 823
Oil Filter Head Removal And Installation 824
Oil Cooler Bypass Description 825
Oil Cooler Bypass Removal And Installation 825
FUEL SYSTEM 827
Description 827
Fuel Filter Housing Removal And Installation 828
Fuel Lift Pump Removal And Installation 830
Transfer Pump / High Pressure Pump Removal And Installation 830
Fuel Temperature Sensor Removal And Installation 832
Fuel Cooler Removal And Installation 833
Fuel Recirculation Valve (FRV) Removal And Installation 833
Fuel Injector Removal And Installation 834
Injector Coding 836
CYLINDER HEAD 837
Glow Plugs Testing 837
Glow Plug Removal And Installation 838
Valve Clearance Adjustment 839
Cylinder Head Removal And Installation 841
Cylinder Head Disassembly And Assembly 845
Cylinder Head Inspection 846
Cylinder Head Top Clearance 847
Valve Step Height 848
Valve Stem Height 848
Valve Guide 849
Valve 849
Valve Spring 850
Rocker Arm Shaft Disassembly And Assembly 851
Rocker Arm Shaft Inspection 852
Push Rod Inspection 852
CRANKSHAFT AND PISTONS 853
Piston And Connecting Rod Removal And Installation 853
Piston And Connecting Rod Inspection 854
Crankshaft Removal And Installation 856
Cylinder Block Inspection 859
Crankshaft Inspection 861
Connecting Rod Inspection 861
Engine Component Class 862
CAMSHAFT 865
Removal And Installation 865
Inspecting 866
GEARCASE 869
Gearcase Cover Removal And Installation 869
Gear Backlash 870
Gear Timing 871
Idle Gear Removal And Installation 872
Idle Gear Inspection 872
TURBOCHARGER 873
Description 873
Removal And Installation 873
Inspection 876
FLYWHEEL AND HOUSING 877
Flywheel Removal And Installation 877
Ring Gear Removal And Installation 878
Housing Removal And Installation 878
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 879
Description 879
Removal And Installation 880
Disassembly And Assembly 884
HEATING AND VENTILATION 887
REGULAR MAINTENANCE 889
Filters 889
Heater Coil 890
TROUBLESHOOTING 893
Blower Motor Does Not Operate 893
Blower Motor Operates Normally, But Air Flow Is Insufficient 893
Troubleshooting Tree 894
Electrical System 896
Engine Coolant Bypassing The Heater Valve 899
Heater Valve Not Opening Or Closing 900
HEATER UNIT 901
Removal And Installation 901
HEATER COIL 903
Removal And Installation 903
BLOWER FAN 905
Removal And Installation 905
Disassembly And Assembly 905
HEATER VALVE 909
Removal And Installation 909
EVAPORATOR / HEATER COVER 911
Removing 911
Installing 911
SPECIFICATIONS 913
LOADER SPECIFICATIONS 915
Machine Dimensions 915
Performance 916
Engine 916
Drive System 917
Controls 917
Hydraulic System 918
Electrical System 919
Capacities 919
Tires 920
TECHINCAL SERVICE GUIDE SPECIFICATIONS 921
Engine 921
Engine Torques 921
Cooling System 921
Loader Torques 922
Hydraulic / Hydrostatic System 922
Fuel Consumption 922
TORQUE SPECIFICATIONS FOR BOLTS 923
Torque For General SAE Bolts 923
Torque For General Metric Bolts 924
HYDRAULIC CONNECTION SPECIFICATIONS 925
Straight Thread O-ring Fitting 925
Flare Fitting 926
Tubelines And Hoses 926
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 927
Specifications 927
CONVERSIONS 929
Decimal And Millimeter Equivalent Chart 929
U S To Metric Conversion Chart 929
SERVICE TOOLS REQUIRED 931
Remote Start Tools 931
Hydraulic Tools 932
Mainframe And Drive Tools 935
Electrical Tools 938
Engine Tools 939
HVAC Tools 944
ALPHABETICAL INDEX 945

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