Bobcat S570 Skid-Steer Loader Service Manual 6990681 – PDF DOWNLOAD

Description

Bobcat S570 Skid-Steer Loader Service Manual 6990681 – PDF DOWNLOAD

FILE DETAILS:

Bobcat S570 Skid-Steer Loader Service Manual 6990681 – PDF DOWNLOAD

Language : English
Pages : 1326
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S570 Skid-Steer Loader Service Manual 6990681 – 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 S570 Skid-Steer Loader Service Manual 6990681 – 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 40
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
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 111
HYDRAULIC SYSTEM INFORMATION 127
Glossary Of Hydraulic / Hydrostatic Symbols 127
Troubleshooting 131
CYLINDER (LIFT) 133
Testing 133
Removal And Installation 134
Parts Identification 137
Disassembly 138
Assembly 140
CYLINDER (TILT) 143
Testing 143
Removal And Installation 144
Base End Pivot Pin Removal And Installation 145
Parts Identification 146
Disassembly 147
Assembly 149
CYLINDER (LIFT) (B3GZ11341 & ABOVE) 153
Testing 153
Removal And Installation 154
Parts Identification 158
Disassembly 159
Assembly 161
CYLINDER (TILT) (B3GZ11341 & ABOVE) 165
Testing 165
Removal And Installation 166
Base End Pivot Pin Removal And Installation 167
Parts Identification 168
Disassembly 169
Assembly 171
CYLINDER (BOB-TACH) 175
Testing 175
Removal And Installation 176
Parts Identification 177
Disassembly 178
Assembly 179
MAIN RELIEF VALVE 183
Description 183
Testing 184
Adjusting 186
Removal And Installation 187
HYDRAULIC CONTROL VALVE (STANDARD) 189
Description 189
Removal And Installation 190
Mount Bracket Removal And Installation 193
Identification Chart 194
Lift Load Check Valve Removal And Installation 195
Load Check Valve Removal And Installation (Tilt And Auxiliary) 196
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 197
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 197
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 198
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 198
Port Relief Valve Removal And Installation 199
Plug Removal And Installation 201
Rubber Boot Removal And Installation 202
End Cap Block Removal And Installation 202
Lift Spool And Detent Removal And Installation 203
Tilt Spool Removal And Installation 211
Auxiliary Spool Removal And Installation 213
Auxiliary Solenoid Removal And Installation 214
Solenoid Removal And Installation 215
Lock Valve Removal And Installation 216
Lift Arm Bypass Orifice Removal And Installation 218
Main Relief Valve Removal And Installation 218
Check Valve Removal And Installation 219
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 221
Description 221
Removal And Installation 221
Actuator Removal And Installation (In Loader) 226
Actuator Removal And Installation (Out Of Loader) 228
Identification Chart 231
Mount Bracket Removal And Installation 232
Lift Load Check Valve Removal And Installation 232
Load Check Valve Removal And Installation (Tilt And Auxiliary) 233
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 234
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 234
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 235
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 235
Port Relief Valve Removal And Installation 236
Plug Removal And Installation 238
End Cap Block Removal And Installation 239
Lift Spool Removal And Installation 239
Lift Spool Disassembly And Assembly 241
Tilt Spool Removal And Installation 242
Auxiliary Spool Removal And Installation 244
Auxiliary Solenoid Removal And Installation 245
Solenoid Removal And Installation 246
Lock Valve Removal And Installation 247
Lift Arm Bypass Orifice Removal And Installation 249
Main Relief Valve Removal And Installation 249
Check Valve Removal And Installation 250
LIFT ARM BYPASS CONTROL VALVE 251
Description 251
Testing 251
Removal And Installation 252
Bracket Removal And Installation 253
Disassembly And Assembly 253
HYDRAULIC PUMP 255
Description 255
Pump Test At Quick Couplers 256
Direct Pump Test (Standard Section) 258
Direct Pump Test (Charge Section) 260
Removal And Installation 262
Hydraulic Pump Startup 264
Parts Identification 265
Disassembly And Assembly 266
HYDRAULIC PUMP (HIGH FLOW) 267
Description 267
Pump Test At Quick Couplers 268
Direct Pump Test (Standard Section) 270
Direct Pump Test (Charge Section) 271
Direct Pump Test (High Flow Section) 273
High Flow Relief Valve Adjustment 275
High Flow Relief Valve Removal And Installation 277
Solenoid Removal And Installation 278
Removal And Installation 279
Hydraulic Pump Startup 281
Parts Identification 282
Disassembly And Assembly 283
HYDRAULIC / HYDROSTATIC FILTERS 285
Description 285
Housing Removal And Installation 285
HYDRAULIC FLUID RESERVOIR 287
Description 287
Removal And Installation 287
Hydraulic Fluid Screen 288
OIL COOLER 289
Removal And Installation 289
BUCKET POSITION VALVE 291
Description 291
Solenoid Removal And Installation 291
Solenoid Testing 293
Removal And Installation 293
Disassembly And Assembly 295
REAR AUXILIARY DIVERTER VALVE 297
Description 297
Solenoid Testing 297
Removal And Installation 298
Disassembly And Assembly 299
BOB-TACH (POWER) BLOCK (S/N ALM411001 – ALM413900) 305
Description 305
Removal And Installation 305
Disassembly And Assembly 307
BOB-TACH (POWER) BLOCK (S/N ALM413901 AND B3GZ11001 & ABOVE) 315
Description 315
Testing Relief Valve 316
Removal And Installation 317
Disassembly And Assembly 319
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 325
Description 325
Removal And Installation 326
Disassembly And Assembly (FFI/FI) 326
Disassembly And Assembly (FFH/FH) 328
AUTOMATIC RIDE CONTROL 331
Description 331
Removal And Installation 332
Checking The Pressure In The Accumulator 335
Adding Nitrogen To The Accumulator 337
HYDROSTATIC SYSTEM 339
HYDROSTATIC SYSTEM INFORMATION 341
Description 341
Troubleshooting 342
HYDROSTATIC DRIVE MOTOR 343
Description 343
Removal And Installation 343
Parts Identification 346
Disassembly And Assembly 347
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 353
Description 353
Removal And Installation (Left Side) 354
Removal And Installation (Right Side) 357
Parts Identification 360
Disassembly 361
Assembly 374
HYDROSTATIC MOTOR CARRIER 389
Description 389
Shaft Seal Removal And Installation 390
Removal And Installation 392
Parts Identification 394
Disassembly 395
Assembly 397
HYDROSTATIC MOTOR CARRIER (TWO-SPEED) 401
Description 401
Shaft Seal Removal And Installation 402
Removal And Installation 404
Parts Identification 406
Disassembly 407
Assembly 409
CHARGE PRESSURE 413
Description 413
Testing 414
Adjusting 416
Sender Removal And Installation (Earlier Models) 418
Sender Removal And Installation (Later Models) 418
HYDROSTATIC PUMP 419
Description 419
Removal And Installation 420
Hydrostatic Pump Startup 421
Replenishing / High Pressure Relief Valve Removal And Installation 422
Parts Identification (Left Half) 423
Parts Identification (Right Half) 424
Disassembly 425
Assembly 432
HYDROSTATIC PUMP (SJC) 439
Description 439
Hydraulic Controller Removal And Installation 440
Removal And Installation 442
Hydrostatic Pump Startup 444
Parts Identification 445
High Pressure Relief And Bypass Valve 446
Charge Relief Valve 447
Disassembly And Assembly 448
Mechanical Neutral Adjustment 461
Hydraulic Controller Neutral Adjustment 464
HYDROSTATIC PUMP (SJC) (S/N ALM425401 & ABOVE) 467
Description 467
Port Locations And Gauge Installation 468
Removal And Installation 469
Hydrostatic Pump Startup 471
Parts Identification 472
High Pressure Relief And Bypass Valve 475
Charge Pressure Relief Valve 476
Disassembly And Assembly 477
Mechanical Neutral Adjustment 489
Hydraulic Controller Neutral Adjustment 491
DRIVE BELT 493
Belt Adjustment 493
Stop Adjustment 493
Belt Replacement 494
Tensioner Pulley Removal And Installation (Earlier Models) 496
Tensioner Pulley Disassembly And Assembly 496
Tensioner Pulley Removal And Installation (Later Models) 497
Tensioner Pulley Disassembly And Assembly 497
TWO-SPEED 499
Valve Block Removal And Installation 499
Valve Block Disassembly And Assembly 500
DRAIN MANIFOLD 501
Description 501
Drain Manifold Removal And Installation 501
DRIVE SYSTEM 503
BRAKE 505
Description 505
Disc Removal And Installation 505
DRIVE COMPONENTS 507
Description 507
Axle Seal Removal And Installation 508
Axle, Sprocket And Bearings Removal And Installation 510
Chain Removal And Installation 515
CHAINCASE 517
Description 517
Front Cover Removal And Installation 517
Center Cover Removal And Installation 518
Rear Cover Removal And Installation 519
MAINFRAME 521
SEAT BAR 525
Description 525
Removal And Installation 525
Disassembly And Assembly 526
Compression Spring Disassembly And Assembly 527
OPERATOR CAB 529
Gas Spring Removal And Installation 529
Gas Spring Bracket Disassembly And Assembly 530
Removal And Installation 530
OPERATOR SEAT 533
Removal And Installation 533
Seat Belt Removal And Installation (Retractable) 533
Seat Belt And Bracket Removal And Installation (Standard) 534
Seat Belt Bracket Removal And Installation 534
OPERATOR SEAT (SUSPENSION) 535
Removal And Installation 535
Slide Rail Removal And Installation 535
Seat Belt Removal And Installation 536
Lower Cushion Removal 536
Lower Cushion Installation 537
Back Cushion Removal And Installation 537
Shock Removal And Installation 538
3-Point Seat Belt Removal And Installation 538
BOB-TACH (HAND LEVER) 541
Description 541
Removal And Installation 541
Lever And Wedge Disassembly And Assembly 544
Pivot Pin Bushing And Seal Removal And Installation 546
BOB-TACH (POWER) 547
Description 547
Removal And Installation 547
Lever And Wedge Disassembly And Assembly 550
Pivot Pin Bushing And Seal Removal And Installation 552
LIFT ARMS 553
Stabilizer Bar Removal And Installation 553
Link Removal And Installation 554
Removal And Installation 555
REAR GRILLE 559
Removing 559
Installing 559
Shield Removal And Installation 560
REAR DOOR (TAILGATE) 561
Removal And Installation 561
Striker Removal And Installation 562
Striker Disassembly And Assembly 562
Striker Adjusting 563
Latch Removal And Installation 564
FUEL TANK 565
Removal And Installation 565
Fuel Level Sender Removal And Installation 567
Fuel Fill Screen Removal And Installation 567
CONTROL PEDALS AND LINKAGES 569
Description 569
Pedal Removal And Installation 569
Linkage Removal And Installation 570
Pedal (Adjusting) 571
Floor Pan Removal And Installation 572
CONTROL PEDALS AND LINKAGES (ACS) 573
Description 573
Pedal Removal And Installation 573
Linkage Removal And Installation 574
Pedal (Adjusting) 574
Floor Pan Removal And Installation 575
CONTROL PANEL 577
Description 577
Removal And Installation 578
Disassembly And Assembly 579
Linkage Removal And Installation 583
Pintle Arm Disassembly And Assembly 587
Linkage Neutral (Adjusting) 588
Linkage Travel (Adjusting) 592
Shock Removal And Installation 596
CONTROL PANEL (SJC) 597
Description 597
Removal And Installation 597
CONTROL HANDLE / LEVER 599
Description 599
Lever Removal And Installation 599
Boot Removal And Installation 600
CONTROL HANDLE / LEVER (ACS) 601
Description 601
Handle Sensor Removal And Installation 601
Handle Removal And Installation 604
Handle Disassembly And Assembly 605
Lever Removal And Installation 605
Boot Removal And Installation 606
CONTROL HANDLE / LEVER (SJC) 607
Description 607
Joystick Testing 607
Joystick Removal And Installation 608
ACCESS PANEL (INSIDE) 609
Removal And Installation (Left) 609
Removal And Installation (Right) 609
ACCESS PANEL (INSIDE) (SJC) 611
Removal And Installation (Left) 611
Removal And Installation (Right) 611
WINDOW (REAR) 613
Rear Window Identification 613
Rear Window Removal (Latches) 613
Rear Window Removal (Rubber Cord) 613
External Access (Rear Window With Latches) 614
External Access (Rear Window With Rubber Cord) 614
Disassembly And Assembly (Latches) 615
WINDOW (TOP) 617
Removal And Installation 617
WINDOW (SIDE) 619
Removal And Installation 619
CAB DOOR 621
Description 621
Removal And Installation 621
Disassembly And Assembly 622
Aligning 623
Adjusting 624
Checking Operation 624
ARMREST 625
Description 625
Removal And Installation 626
Disassembly And Assembly 627
LEFT SIDE LOWER PANEL 629
Removal And Installation 629
Disassembly And Assembly 632
RIGHT SIDE LOWER PANEL 633
Removal And Installation 633
Disassembly And Assembly 635
HEADLINER 637
Removal And Installation 637
FAN DUCT PANELS 639
Removal And Installation 639
ELECTRICAL SYSTEM 641
ELECTRICAL SCHEMATICS 647
ELECTRICAL SYSTEM INFORMATION 889
Glossary Of Electrical Symbols 889
Standard Cab Harness Connectors 892
Deluxe Cab Harness Connectors 893
Mainframe Harness Connectors – Manual Controls 894
Mainframe Harness Connectors – SJC 895
Engine Harness Connectors 896
Description 897
Troubleshooting 898
Fuse And Relay Location / Identification 899
Solenoid Testing 904
BATTERY 905
Removal And Installation 905
Battery Maintenance 906
Maintaining Battery Charge Level 906
Battery Service During Machine Storage 906
Battery Testing 907
Battery Charging 907
Using A Booster Battery (Jump Starting) 908
ALTERNATOR 909
Belt Adjustment 909
Belt Replacement 910
Charging System Inspection 911
Alternator Voltage Testing 912
Low Voltage Testing 912
High Voltage Testing 913
Removal And Installation 914
Parts Identification 916
STARTER 917
Testing 917
Removal And Installation 917
Parts Identification 918
INSTRUMENT PANELS 919
Left Panel 919
Display Screen 921
Right Panel (Standard Key Panel) 922
Right Panel (Keyless Start Panel) 923
Right Panel (Deluxe Instrumentation Panel) 924
Left Switch Panel 926
Right Switch Panel 926
Left Side Lower Panel 927
Right Side Lower Panel 927
Left Panel Removal And Installation 928
Right Panel (Standard Key Panel) Removal And Installation 928
Right Panel (Keyless Start Panel) Removal And Installation 929
Right Panel (Deluxe Instrumentation Panel) Removal And Installation 929
Key Switch Disassembly And Assembly 930
Alarm Disassembly And Assembly 930
Left Switch Panel Removal And Installation 931
Right Switch Panel Removal And Installation 931
LIGHTS 933
Front Removal And Installation 933
Rear Removal And Installation 934
Cab Light Removal And Installation (Earlier Models) 934
Cab Light Removal And Installation (Later Models) 935
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) 937
Description 937
Connector Identification 938
Removal And Installation 944
BOBCAT CONTROLLER (ACS) 945
Description 945
Connector And Wire Identification 946
Removal And Installation 947
BOBCAT CONTROLLER (SJC) (DRIVE) 949
Description 949
Connector Identification 950
Removal And Installation 952
ENGINE CONTROL UNIT (ECU) 953
Description 953
Cleaning 954
Removal And Installation 955
DIAGNOSTIC SERVICE CODES 957
Viewing Service Codes 957
Service Codes List 958
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 967
Description 967
Inspecting The BICS™ (Engine STOPPED – Key ON) 968
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 968
Inspecting The Seat Bar Sensor (Engine RUNNING) 968
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 968
Inspecting The Lift Arm Bypass Control 968
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) 968
Troubleshooting 969
SEAT BAR SENSOR 971
Description 971
Troubleshooting 971
Testing 972
Removal 973
Installation 975
Bobcat Interlock Control System (BICS™) Circuit Test 976
TRACTION LOCK 979
Description 979
Troubleshooting 980
Inspecting 981
CONTROL SYSTEM (ACS) 983
Description 983
Troubleshooting 984
Handle Sensor Connector Disassembly And Assembly 985
Switch Handle Removal 986
Switch Handle Installation 988
Actuator Connector Disassembly And Assembly 991
Handle Lock Solenoid Removal And Installation 992
Handle Lock Solenoid Disassembly And Assembly 992
Foot Sensor Removal And Installation 993
Foot Sensor Disassembly And Assembly 994
Foot Sensor Lock Solenoid Removal And Installation 994
ELECTRICAL / HYDRAULIC CONTROLS 995
Identification Chart 995
Description 996
Identification Chart ACD Group 0 997
Identification Chart ACD Group 1 998
Identification Chart ACD Group 2 999
Identification Chart ACD Group 3 1000
ELECTRICAL / HYDRAULIC CONTROLS (ACS) 1001
Identification Chart 1001
Description 1002
Identification Chart ACD Group 0 1003
Identification Chart ACD Group 1 1004
Identification Chart ACD Group 2 1005
Identification Chart ACD Group 3 1006
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 1007
Identification Chart 1007
Description 1008
Identification Chart ACD Group 0 1009
Identification Chart ACD Group 1 1010
Identification Chart ACD Group 2 1011
Identification Chart ACD Group 3 1012
SERVICE PC (LAPTOP COMPUTER) 1013
Connecting Remote Start Tool 1013
Connecting Remote Start Tool (Service Tool) 1013
CALIBRATION 1015
Description 1015
Actuator Testing 1015
Lift And Tilt Calibration (SJC) 1018
Hydrostatic Pump Calibration (SJC) 1020
Lift And Tilt Calibration (ACS) 1025
STEERING DRIFT COMPENSATION (OPERATOR MODE) 1027
Description 1027
Operation 1027
STEERING DRIFT COMPENSATION (SERVICE MODE) 1029
Description 1029
Operation 1029
CONTROL PANEL SETUP 1031
Right Panel Setup (Deluxe Instrumentation Panel) 1031
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 1035
Password Description 1035
Changing The Owner Password 1035
Changing The User Passwords 1036
Password Lockout Feature 1036
PASSWORD SETUP (KEYLESS START PANEL) 1037
Password Description 1037
Changing The Owner Password 1037
Password Lockout Feature 1037
MAINTENANCE CLOCK 1039
Description 1039
Setup 1040
Reset 1043
BACK-UP ALARM SYSTEM 1045
Description 1045
Inspecting 1045
Adjusting Switch Position 1046
Troubleshooting (Standard And ACS) 1047
Troubleshooting (Joystick) 1048
Alarm Removal And Installation 1049
Switch Removal And Installation 1049
FRONT HORN 1051
Removal And Installation 1051
Troubleshooting 1052
Troubleshooting (Joystick) 1053
ENGINE SPEED CONTROL (HAND) 1055
Removal And Installation 1055
ENGINE SPEED CONTROL (FOOT) 1057
Removal And Installation 1057
Disassembly And Assembly 1058
Foot Throttle Calibration 1060
CAMSHAFT AND CRANKSHAFT POSITION SENSOR 1063
Removal And Installation 1063
TELEMATICS 1065
Description 1065
Removal And Installation 1065
Procedure 1066
ENGINE SERVICE 1067
ENGINE INFORMATION 1071
Description 1071
Specifications 1072
Sensor Location 1074
Torque Values 1080
Troubleshooting 1082
Engine Removal And Installation 1084
Engine Mount Replacement 1093
Compression – Testing 1095
Injector Signal – Testing 1097
Injector Signal – Testing (In-Line) 1099
Oil Pressure Testing (At Oil Sensor On Block) 1101
Oil Pressure Testing (At Turbocharger Oil Inlet) 1103
DIESEL OXIDATION CATALYST (DOC) 1105
Removal And Installation 1105
AIR CLEANER 1107
Housing Removal And Installation 1107
ENGINE COOLING SYSTEM (EARLIER MODELS) 1109
Radiator / Oil Cooler Removal And Installation 1109
Hydraulic Fan Description 1112
Fan Duct Removal And Installation 1112
Hydraulic Fan Motor Assembly Removal And Installation 1113
Hydraulic Fan Motor Removal And Installation 1114
Hydraulic Fan Motor Disassembly And Assembly 1116
Blower Housing Removal And Installation 1117
Water Pump Removal And Installation 1118
Thermostat Housing Removal And Installation 1119
Testing The Thermostat 1120
ENGINE COOLING SYSTEM (LATER MODELS) 1121
Radiator / Oil Cooler Removal And Installation 1121
Hydraulic Fan Description 1124
Reversible Hydraulic Fan Description 1124
Fan Duct Removal And Installation 1124
Hydraulic Fan Motor Assembly Removal And Installation 1125
Hydraulic Fan Motor Removal And Installation 1126
Hydraulic Fan Motor Disassembly And Assembly 1128
Hydraulic Fan Motor Assembly Removal And Installation 1136
Hydraulic Fan Motor Removal And Installation 1137
Hydraulic Fan Motor Disassembly And Assembly 1139
Blower Housing Removal And Installation 1144
Water Pump Removal And Installation 1145
Thermostat Housing Removal And Installation 1146
Testing The Thermostat 1147
LUBRICATION SYSTEM 1149
Description 1149
Oil Pan Removal And Installation 1150
Oil Pump Removal And Installation 1151
Oil Pump Relief Valve Description 1152
Oil Pump Relief Valve Removal And Installation 1152
Oil Cooler Removal And Installation 1153
Oil Filter Head Removal And Installation 1154
Oil Cooler Bypass Description 1155
Oil Cooler Bypass Removal And Installation 1155
FUEL SYSTEM 1157
Description 1157
Transfer Pump / High Pressure Pump Removal And Installation 1158
Fuel Temperature Sensor Removal And Installation 1160
Fuel Cooler Removal And Installation 1161
Fuel Bypass Valve Removal And Installation 1161
Fuel Recirculation Valve Removal And Installation 1162
Fuel Rail Assembly Removal And Installation 1163
Fuel Injector Removal And Installation 1164
Injector Coding 1166
Removing Air From The Fuel System 1168
CYLINDER HEAD 1171
Glow Plugs Testing 1171
Glow Plug Removal And Installation 1172
Valve Clearance Adjustment 1173
Cylinder Head Removal And Installation 1175
Cylinder Head Disassembly And Assembly 1179
Cylinder Head Inspection 1180
Cylinder Head Top Clearance 1181
Valve Step Height 1182
Valve Stem Height 1182
Valve Guide 1183
Valve 1183
Valve Spring 1184
Rocker Arm Shaft Disassembly And Assembly 1185
Rocker Arm Shaft Inspection 1186
Push Rod Inspection 1186
CRANKSHAFT AND PISTONS 1187
Piston And Connecting Rod Removal And Installation 1187
Piston And Connecting Rod Inspection 1188
Crankshaft Removal And Installation 1190
Cylinder Block Inspection 1193
Crankshaft Inspection 1195
Connecting Rod Inspection 1195
Engine Component Class 1196
CAMSHAFT 1199
Removal And Installation 1199
Inspecting 1200
GEARCASE 1203
Gearcase Cover Removal And Installation 1203
Gear Backlash 1204
Gear Timing 1205
Idle Gear Removal And Installation 1206
Idle Gear Inspection 1206
TURBOCHARGER 1207
Description 1207
Removal And Installation 1207
Inspection 1210
FLYWHEEL AND HOUSING 1211
Flywheel Removal And Installation 1211
Ring Gear Removal And Installation 1212
Housing Removal And Installation 1212
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 1213
Description 1213
Removal And Installation 1214
Disassembly And Assembly 1218
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1221
AIR CONDITIONING SYSTEM FLOW 1223
Description 1223
Chart 1224
Components 1225
Safety Equipment 1228
REGULAR MAINTENANCE 1229
Filters 1229
Belt Adjustment 1230
Belt Replacement 1230
Air Conditioning Condenser 1230
Air Conditioning Lubrication 1230
Air Conditioning Service Chart 1231
Evaporator / Heater Coil 1232
TROUBLESHOOTING 1235
Blower Motor Does Not Operate 1235
Blower Motor Operates Normally, But Air Flow Is Insufficient 1235
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 1235
The Compressor Does Not Operate At All, Or Operates Improperly 1235
Gauge Pressure Related Troubleshooting 1236
Troubleshooting Tree 1238
Temperature / Pressure Chart 1242
Poor A/C Performance 1244
HVAC Repair And Leaks 1245
Electrical System 1246
Engine Coolant Bypassing The Heater Valve 1252
Heater Valve Not Opening Or Closing 1253
SYSTEM CHARGING AND RECLAMATION 1255
Refrigerant Identification 1255
Reclamation And Charging With Recovery / Charging Unit 1256
COMPRESSOR 1259
Removal And Installation 1259
Oil 1261
Oil Check 1262
CONDENSER 1265
Removal And Installation 1265
RECEIVER / DRIER 1267
Receiver / Drier Removal And Installation 1267
Pressure Switch Removal And Installation 1269
Schrader® Valve Removal And Installation 1270
EVAPORATOR / HEATER UNIT 1271
Removal And Installation 1271
THERMOSTAT 1273
Description 1273
Removal And Installation 1274
EXPANSION VALVE 1275
Removal And Installation 1275
EVAPORATOR COIL 1277
Removal And Installation 1277
HEATER COIL 1279
Removal And Installation 1279
BLOWER FAN 1281
Removal And Installation 1281
Disassembly And Assembly 1281
HEATER VALVE 1285
Removal And Installation 1285
EVAPORATOR / HEATER COVER 1287
Removing 1287
Installing 1287
SPECIFICATIONS 1289
(S570) LOADER SPECIFICATIONS 1291
Machine Dimensions 1291
Performance 1292
Engine 1292
Drive System 1293
Controls 1293
Hydraulic System 1294
Electrical System 1295
Capacities 1295
Tires 1296
TECHINCAL SERVICE GUIDE SPECIFICATIONS 1297
Engine 1297
Engine Torques 1297
Cooling System 1297
Loader Torques 1298
Hydraulic / Hydrostatic System 1298
Fuel Consumption 1298
TORQUE SPECIFICATIONS FOR BOLTS 1299
Torque For General SAE Bolts 1299
Torque For General Metric Bolts 1300
HYDRAULIC CONNECTION SPECIFICATIONS 1301
Straight Thread O-ring Fitting 1301
Flare Fitting 1302
Tubelines And Hoses 1302
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 1303
Specifications 1303
CONVERSIONS 1305
Decimal And Millimeter Equivalent Chart 1305
U S To Metric Conversion Chart 1305
SERVICE TOOLS REQUIRED 1307
Remote Start Tools 1307
Hydraulic Tools 1308
Mainframe And Drive Tools 1311
Electrical Tools 1314
Engine Tools 1315
HVAC Tools 1320
ALPHABETICAL INDEX 1321

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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