Bobcat S595 Skid-Steer Loader Service Manual SN B3NL11001 & Above – PDF DOWNLOAD

Description

Bobcat S595 Skid-Steer Loader Service Manual SN B3NL11001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat S595 Skid-Steer Loader Service Manual SN B3NL11001 & Above – PDF DOWNLOAD

Language : English
Pages : 1196
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S595 Skid-Steer Loader Service Manual SN B3NL11001 & 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 S595 Skid-Steer Loader Service Manual SN B3NL11001 & 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 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 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 66
ENGINE LUBRICATION SYSTEM 67
Checking And Adding Engine Oil 67
Engine Oil Chart 67
Removing And Replacing Oil And Filter 68
HYDRAULIC / HYDROSTATIC SYSTEM 71
Checking And Adding Fluid 71
Hydraulic / Hydrostatic Fluid Chart 71
Removing And Replacing Hydraulic Fluid 72
Removing And Replacing Hydraulic / Hydrostatic Filter 74
Removing And Replacing Hydraulic Charge Filter 75
Replacing Reservoir Breather Cap 76
FINAL DRIVE TRANSMISSION (CHAINCASE) 77
Checking And Adding Fluid 77
Removing And Replacing Fluid 77
BOB-TACH (HAND LEVER) 79
Inspection And Maintenance 79
BOB-TACH (POWER) 81
Inspection And Maintenance 81
LUBRICATING THE LOADER 83
Lubrication Locations 83
TIRE MAINTENANCE 87
Wheel Nuts 87
Rotating 87
Mounting 88
PIVOT PINS 89
Inspection And Maintenance 89
LOADER STORAGE AND RETURN TO SERVICE 91
Storage 91
Return To Service 91
STOPPING THE ENGINE AND LEAVING THE LOADER 93
Procedure 93
EMERGENCY EXIT 95
Rear Window Identification 95
Rear Window Removal (Latches) 95
Rear Window Removal (Rubber Cord) 95
External Access (Rear Window With Latches) 96
External Access (Rear Window With Rubber Cord) 96
Front Door 96
SEAT BELT 99
Inspection And Maintenance 99
HYDRAULIC SYSTEM 101
HYDRAULIC/HYDROSTATIC SCHEMATIC 105
HYDRAULIC SYSTEM INFORMATION 117
Glossary Of Hydraulic / Hydrostatic Symbols 117
Troubleshooting 121
CYLINDER (LIFT) 123
Testing 123
Removal And Installation 124
Parts Identification 128
Disassembly 129
Assembly 131
CYLINDER (TILT) 135
Testing 135
Removal And Installation 136
Base End Pivot Pin Removal And Installation 137
Parts Identification 138
Disassembly 139
Assembly 141
CYLINDER (BOB-TACH) 145
Testing 145
Removal And Installation 146
Parts Identification 147
Disassembly 148
Assembly 150
MAIN RELIEF VALVE 153
Description 153
Testing 154
Adjusting 156
Removal And Installation 157
HYDRAULIC CONTROL VALVE (STANDARD) 159
Description 159
Removal And Installation 160
Mount Bracket Removal And Installation 163
Identification Chart 164
Lift Load Check Valve Removal And Installation 165
Load Check Valve Removal And Installation (Tilt And Auxiliary) 166
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 167
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 167
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 168
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 168
Port Relief Valve Removal And Installation 169
Plug Removal And Installation 171
Rubber Boot Removal And Installation 172
End Cap Block Removal And Installation 172
Lift Spool And Detent Removal And Installation 173
Tilt Spool Removal And Installation 181
Auxiliary Spool Removal And Installation 183
Auxiliary Solenoid Removal And Installation 184
Solenoid Removal And Installation 185
Lock Valve Removal And Installation 186
Lift Arm Bypass Orifice Removal And Installation 188
Main Relief Valve Removal And Installation 188
Check Valve Removal And Installation 189
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 191
Description 191
Removal And Installation 191
Actuator Removal And Installation (In Loader) 196
Actuator Removal And Installation (Out Of Loader) 198
Identification Chart 201
Mount Bracket Removal And Installation 202
Lift Load Check Valve Removal And Installation 202
Load Check Valve Removal And Installation (Tilt And Auxiliary) 203
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 204
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 204
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 205
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 205
Port Relief Valve Removal And Installation 206
Plug Removal And Installation 208
End Cap Block Removal And Installation 209
Lift Spool Removal And Installation 209
Lift Spool Disassembly And Assembly 211
Tilt Spool Removal And Installation 212
Auxiliary Spool Removal And Installation 214
Auxiliary Solenoid Removal And Installation 215
Solenoid Removal And Installation 216
Lock Valve Removal And Installation 217
Lift Arm Bypass Orifice Removal And Installation 219
Main Relief Valve Removal And Installation 219
Check Valve Removal And Installation 220
LIFT ARM BYPASS CONTROL VALVE 221
Description 221
Testing 221
Removal And Installation 222
Bracket Removal And Installation 223
Disassembly And Assembly 223
HYDRAULIC PUMP 225
Description 225
Pump Test At Quick Couplers 226
Direct Pump Test (Standard Section) 228
Direct Pump Test (Charge Section) 230
Removal And Installation 232
Hydraulic Pump Startup 234
Parts Identification 235
Disassembly And Assembly 236
HYDRAULIC PUMP (HIGH FLOW) 237
Description 237
Pump Test At Quick Couplers 238
Direct Pump Test (Standard Section) 240
Direct Pump Test (Charge Section) 241
Direct Pump Test (High Flow Section) 243
High Flow Relief Valve Adjustment 245
High Flow Relief Valve Removal And Installation 247
Solenoid Removal And Installation 248
Removal And Installation 249
Hydraulic Pump Startup 251
Parts Identification 252
Disassembly And Assembly 253
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 259
Removal And Installation 259
BUCKET POSITION VALVE 261
Description 261
Solenoid Removal And Installation 261
Solenoid Testing 263
Removal And Installation 263
Disassembly And Assembly 265
REAR AUXILIARY DIVERTER VALVE 267
Description 267
Solenoid Testing 267
Removal And Installation 268
Disassembly And Assembly 269
BOB-TACH (POWER) BLOCK 275
Description 275
Testing Relief Valve 276
Removal And Installation 278
Disassembly And Assembly 280
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 285
Description 285
Removal And Installation 286
Disassembly And Assembly (FFI/FI) 286
Disassembly And Assembly (FFH/FH) 288
AUTOMATIC RIDE CONTROL 291
Description 291
Removal And Installation 292
Checking The Pressure In The Accumulator 295
Adding Nitrogen To The Accumulator 297
HYDROSTATIC SYSTEM 299
HYDROSTATIC SYSTEM INFORMATION 301
Description 301
Troubleshooting 302
HYDROSTATIC DRIVE MOTOR 303
Description 303
Removal And Installation 303
Parts Identification 306
Disassembly And Assembly 307
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 313
Description 313
Removal And Installation (Left Side) 314
Removal And Installation (Right Side) 317
Parts Identification 320
Disassembly 321
Assembly 333
HYDROSTATIC MOTOR CARRIER 347
Description 347
Shaft Seal Removal And Installation 348
Removal And Installation 350
Parts Identification 352
Disassembly 353
Assembly 355
HYDROSTATIC MOTOR CARRIER (TWO-SPEED) 359
Description 359
Shaft Seal Removal And Installation 360
Removal And Installation 362
Parts Identification 364
Disassembly 365
Assembly 367
CHARGE PRESSURE 371
Description 371
Testing 372
Adjusting 374
Sender Removal And Installation 377
HYDROSTATIC PUMP 379
Description 379
Removal And Installation 380
Hydrostatic Pump Startup 381
Replenishing / High Pressure Relief Valve Removal And Installation 382
Parts Identification (Left Half) 383
Parts Identification (Right Half) 384
Disassembly 385
Assembly 392
HYDROSTATIC PUMP (SJC) 399
Description 399
Hydraulic Controller Removal And Installation 400
Removal And Installation 402
Hydrostatic Pump Startup 404
Parts Identification 405
High Pressure Relief And Bypass Valve 406
Charge Relief Valve 407
Disassembly And Assembly 408
Mechanical Neutral Adjustment 421
Hydraulic Controller Neutral Adjustment 424
HYDROSTATIC PUMP (SJC) (S/N B3NL16501 & ABOVE) 427
Description 427
Port Locations And Gauge Installation 428
Removal And Installation 429
Hydrostatic Pump Startup 431
Parts Identification 432
High Pressure Relief And Bypass Valve 435
Charge Pressure Relief Valve 436
Disassembly And Assembly 437
Mechanical Neutral Adjustment 449
Hydraulic Controller Neutral Adjustment 451
DRIVE BELT 453
Belt Adjustment 453
Stop Adjustment 453
Belt Replacement 454
Tensioner Pulley Removal And Installation (Earlier Models) 456
Tensioner Pulley Disassembly And Assembly 456
Tensioner Pulley Removal And Installation (Later Models) 457
Tensioner Pulley Disassembly And Assembly 457
TWO-SPEED 459
Valve Block Removal And Installation 459
Valve Block Disassembly And Assembly 460
DRAIN MANIFOLD 461
Description 461
Drain Manifold Removal And Installation 461
DRIVE SYSTEM 463
BRAKE 465
Description 465
Disc Removal And Installation 465
DRIVE COMPONENTS 467
Description 467
Axle Seal Removal And Installation 468
Axle, Sprocket And Bearings Removal And Installation 470
Chain Removal And Installation 474
CHAINCASE 477
Description 477
Front Cover Removal And Installation 477
Center Cover Removal And Installation 478
Rear Cover Removal And Installation 479
MAINFRAME 481
SEAT BAR 485
Description 485
Removal And Installation 485
Disassembly And Assembly 486
Compression Spring Disassembly And Assembly 487
OPERATOR CAB 489
Gas Spring Removal And Installation 489
Gas Spring Bracket Disassembly And Assembly 490
Removal And Installation 490
OPERATOR SEAT 493
Removal And Installation 493
Seat Belt Removal And Installation (Retractable) 493
Seat Belt And Bracket Removal And Installation (Standard) 494
Seat Belt Bracket Removal And Installation 494
OPERATOR SEAT (SUSPENSION) 495
Removal And Installation 495
Slide Rail Removal And Installation 495
Seat Belt Removal And Installation 496
Lower Cushion Removal 496
Lower Cushion Installation 497
Back Cushion Removal And Installation 497
Shock Removal And Installation 498
3-Point Seat Belt Removal And Installation 498
BOB-TACH (HAND LEVER) 501
Description 501
Removal And Installation 501
Lever And Wedge Disassembly And Assembly 503
Pivot Pin Bushing And Seal Removal And Installation 506
BOB-TACH (POWER) 507
Description 507
Removal And Installation 507
Lever And Wedge Disassembly And Assembly 510
Pivot Pin Bushing And Seal Removal And Installation 512
LIFT ARMS 513
Stabilizer Bar Removal And Installation 513
Link Removal And Installation 514
Removal And Installation 515
REAR GRILLE 519
Removing 519
Installing 519
Shield Removal And Installation 520
REAR DOOR (TAILGATE) 521
Removal And Installation 521
Striker Removal And Installation 522
Striker Disassembly And Assembly 522
Striker Adjusting 523
Latch Removal And Installation 524
FUEL TANK 525
Removal And Installation 525
Fuel Level Sender Removal And Installation 527
Fuel Fill Screen Removal And Installation 527
CONTROL PEDALS AND LINKAGES 529
Description 529
Pedal Removal And Installation 529
Linkage Removal And Installation 530
Pedal (Adjusting) 531
Floor Pan Removal And Installation 532
CONTROL PEDALS AND LINKAGES (ACS) 533
Description 533
Pedal Removal And Installation 533
Linkage Removal And Installation 534
Pedal (Adjusting) 534
Floor Pan Removal And Installation 535
CONTROL PANEL 537
Description 537
Removal And Installation 538
Disassembly And Assembly 540
Linkage Removal And Installation 544
Pintle Arm Disassembly And Assembly 547
Linkage Neutral (Adjusting) 548
Linkage Travel (Adjusting) 552
Shock Removal And Installation 556
CONTROL PANEL (SJC) 557
Description 557
Removal And Installation 557
CONTROL HANDLE / LEVER 559
Description 559
Lever Removal And Installation 559
Boot Removal And Installation 560
CONTROL HANDLE / LEVER (ACS) 561
Description 561
Handle Sensor Removal And Installation 561
Handle Removal And Installation 564
Handle Disassembly And Assembly 565
Lever Removal And Installation 565
Boot Removal And Installation 566
CONTROL HANDLE / LEVER (SJC) 567
Description 567
Joystick Testing 567
Joystick Removal And Installation 568
ACCESS PANEL (INSIDE) 569
Removal And Installation (Left) 569
Removal And Installation (Right) 569
ACCESS PANEL (INSIDE) (SJC) 571
Removal And Installation (Left) 571
Removal And Installation (Right) 571
WINDOW (REAR) 573
Rear Window Identification 573
Rear Window Removal (Latches) 573
Rear Window Removal (Rubber Cord) 573
Disassembly And Assembly 574
External Access (Rear Window With Latches) 575
External Access (Rear Window With Rubber Cord) 575
WINDOW (TOP) 577
Removal And Installation 577
WINDOW (SIDE) 579
Removal And Installation 579
CAB DOOR 581
Description 581
Removal And Installation 581
Disassembly And Assembly 582
Aligning 583
Adjusting 584
Checking Operation 584
ARMREST 585
Description 585
Removal And Installation 586
Disassembly And Assembly 587
LEFT SIDE LOWER PANEL 589
Removal And Installation 589
Disassembly And Assembly 591
RIGHT SIDE LOWER PANEL 593
Removal And Installation 593
Disassembly And Assembly 594
HEADLINER 597
Removal And Installation 597
FAN DUCT PANELS 599
Removal And Installation 599
ELECTRICAL SYSTEM 601
ELECTRICAL SCHEMATICS 607
ELECTRICAL SYSTEM INFORMATION 783
Glossary Of Electrical Symbols 783
Standard Cab Harness Connectors 786
Deluxe Cab Harness Connectors 787
Mainframe Harness Connectors – Manual Controls 788
Mainframe Harness Connectors – SJC 789
Engine Harness Connectors 790
Description 791
Troubleshooting 792
Fuse And Relay Location / Identification 793
Solenoid Testing 798
BATTERY 799
Removal And Installation 799
Battery Maintenance 800
Maintaining Battery Charge Level 800
Battery Service During Machine Storage 800
Battery Testing 801
Battery Charging 801
Using A Booster Battery (Jump Starting) 802
ALTERNATOR 803
Belt Adjustment 803
Belt Replacement 803
Charging System Inspection 804
Alternator Voltage Testing 805
Low Voltage Testing 805
High Voltage Testing 806
Removal And Installation 807
Parts Identification 809
STARTER 811
Testing 811
Removal And Installation 811
Parts Identification 812
INSTRUMENT PANEL IDENTIFICATION 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
ENGINE CONTROL UNIT (ECU) 845
Description 845
Cleaning 846
Removal And Installation 847
DIAGNOSTIC SERVICE CODES 849
Viewing Service Codes 849
Service Codes List 850
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 859
Description 859
Inspecting The BICS™ (Engine STOPPED – Key ON) 860
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 860
Inspecting The Seat Bar Sensor (Engine RUNNING) 860
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 860
Inspecting The Lift Arm Bypass Control 860
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) 860
Troubleshooting 861
SEAT BAR SENSOR 863
Description 863
Troubleshooting 863
Testing 864
Removal 865
Installation 867
Bobcat Interlock Control System (BICS™) Circuit Test 868
TRACTION LOCK 871
Description 871
Troubleshooting 872
Inspecting 873
CONTROL SYSTEM (ACS) 875
Description 875
Troubleshooting 876
Handle Sensor Connector Disassembly And Assembly 877
Switch Handle Removal 878
Switch Handle Installation 880
Actuator Connector Disassembly And Assembly 883
Handle Lock Solenoid Removal And Installation 884
Handle Lock Solenoid Disassembly And Assembly 884
Foot Sensor Removal And Installation 885
Foot Sensor Disassembly And Assembly 886
Foot Sensor Lock Solenoid Removal And Installation 886
ELECTRICAL / HYDRAULIC CONTROLS 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 (ACS) 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
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 899
Identification Chart 899
Description 900
Identification Chart ACD Group 0 901
Identification Chart ACD Group 1 902
Identification Chart ACD Group 2 903
Identification Chart ACD Group 3 904
SERVICE PC (LAPTOP COMPUTER) 905
Connecting Remote Start Tool 905
Connecting Remote Start Tool (Service Tool) 905
CALIBRATION 907
Description 907
Actuator Testing 907
Lift And Tilt Calibration (SJC) 910
Hydrostatic Pump Calibration (SJC) 912
Lift And Tilt Calibration (ACS) 917
STEERING DRIFT COMPENSATION (OPERATOR MODE) 919
Description 919
Operation 919
STEERING DRIFT COMPENSATION (SERVICE MODE) 921
Description 921
Operation 921
CONTROL PANEL SETUP 923
Right Panel Setup (Deluxe Instrumentation Panel) 923
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 927
Password Description 927
Changing The Owner Password 927
Changing The User Passwords 928
Password Lockout Feature 928
PASSWORD SETUP (KEYLESS START PANEL) 929
Password Description 929
Changing The Owner Password 929
Password Lockout Feature 929
MAINTENANCE CLOCK 931
Description 931
Setup 932
Reset 935
BACK-UP ALARM SYSTEM 937
Description 937
Inspecting 937
Adjusting Switch Position 938
Troubleshooting (Standard And ACS) 939
Troubleshooting (Joystick) 940
Alarm Removal And Installation 941
Switch Removal And Installation 941
FRONT HORN 943
Removal And Installation 943
Troubleshooting 944
Troubleshooting (Joystick) 945
ENGINE SPEED CONTROL (HAND) 947
Removal And Installation 947
ENGINE SPEED CONTROL (FOOT) 949
Removal And Installation 949
Disassembly And Assembly 950
Foot Throttle Calibration 952
CAMSHAFT AND CRANKSHAFT POSITION SENSOR 955
Removal And Installation 955
TELEMATICS 957
Description 957
Removal And Installation 957
Procedure 958
ENGINE SERVICE 959
ENGINE INFORMATION 963
Description 963
Specifications 964
Sensor Location 966
Torque Values 972
Troubleshooting 974
Engine Removal And Installation 976
Engine Mount Replacement 985
Compression – Testing 987
Injector Signal – Testing 989
Injector Signal – Testing (In-Line) 991
Oil Pressure Testing (At Oil Sensor On Block) 993
Oil Pressure Testing (At Turbocharger Oil Inlet) 995
DIESEL OXIDATION CATALYST (DOC) 997
Removal And Installation 997
AIR CLEANER 999
Housing Removal And Installation 999
ENGINE COOLING SYSTEM 1001
Radiator / Oil Cooler Removal And Installation 1001
Hydraulic Fan Description 1004
Reversible Hydraulic Fan Description 1004
Fan Duct Removal And Installation 1004
Hydraulic Fan Motor Assembly Removal And Installation 1005
Hydraulic Fan Motor Removal And Installation 1006
Hydraulic Fan Motor Disassembly And Assembly 1008
Blower Housing Removal And Installation 1016
Water Pump Removal And Installation 1017
Thermostat Housing Removal And Installation 1018
Testing The Thermostat 1019
LUBRICATION SYSTEM 1021
Description 1021
Oil Pan Removal And Installation 1022
Oil Pump Removal And Installation 1023
Oil Pump Relief Valve Description 1024
Oil Pump Relief Valve Removal And Installation 1024
Oil Cooler Removal And Installation 1025
Oil Filter Head Removal And Installation 1026
Oil Cooler Bypass Description 1027
Oil Cooler Bypass Removal And Installation 1027
FUEL SYSTEM 1029
Description 1029
Transfer Pump / High Pressure Pump Removal And Installation 1030
Fuel Temperature Sensor Removal And Installation 1032
Fuel Cooler Removal And Installation 1033
Fuel Bypass Valve Removal And Installation 1033
Fuel Recirculation Valve Removal And Installation 1034
Fuel Rail Assembly Removal And Installation 1035
Fuel Injector Removal And Installation 1036
Injector Coding 1038
Removing Air From The Fuel System 1040
CYLINDER HEAD 1043
Glow Plugs Testing 1043
Glow Plug Removal And Installation 1044
Valve Clearance Adjustment 1045
Cylinder Head Removal And Installation 1047
Cylinder Head Disassembly And Assembly 1051
Cylinder Head Inspection 1052
Cylinder Head Top Clearance 1053
Valve Step Height 1054
Valve Stem Height 1054
Valve Guide 1055
Valve 1055
Valve Spring 1056
Rocker Arm Shaft Disassembly And Assembly 1057
Rocker Arm Shaft Inspection 1058
Push Rod Inspection 1058
CRANKSHAFT AND PISTONS 1059
Piston And Connecting Rod Removal And Installation 1059
Piston And Connecting Rod Inspection 1060
Crankshaft Removal And Installation 1062
Cylinder Block Inspection 1065
Crankshaft Inspection 1067
Connecting Rod Inspection 1067
Engine Component Class 1068
CAMSHAFT 1071
Removal And Installation 1071
Inspecting 1072
GEARCASE 1075
Gearcase Cover Removal And Installation 1075
Gear Backlash 1076
Gear Timing 1077
Idle Gear Removal And Installation 1078
Idle Gear Inspection 1078
TURBOCHARGER 1079
Description 1079
Removal And Installation 1079
Inspection 1081
FLYWHEEL AND HOUSING 1083
Flywheel Removal And Installation 1083
Ring Gear Removal And Installation 1084
Housing Removal And Installation 1084
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 1085
Description 1085
Removal And Installation 1086
Disassembly And Assembly 1089
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1091
AIR CONDITIONING SYSTEM FLOW 1093
Description 1093
Chart 1094
Components 1095
Safety Equipment 1098
REGULAR MAINTENANCE 1099
Filters 1099
Belt Adjustment 1100
Belt Replacement 1100
Air Conditioning Condenser 1100
Air Conditioning Lubrication 1100
Air Conditioning Service Chart 1101
Evaporator / Heater Coil 1102
TROUBLESHOOTING 1105
Blower Motor Does Not Operate 1105
Blower Motor Operates Normally, But Air Flow Is Insufficient 1105
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 1105
The Compressor Does Not Operate At All, Or Operates Improperly 1105
Gauge Pressure Related Troubleshooting 1106
Troubleshooting Tree 1108
Temperature / Pressure Chart 1112
Poor A/C Performance 1114
HVAC Repair And Leaks 1115
Electrical System 1116
Engine Coolant Bypassing The Heater Valve 1122
Heater Valve Not Opening Or Closing 1123
SYSTEM CHARGING AND RECLAMATION 1125
Refrigerant Identification 1125
Reclamation And Charging With Recovery / Charging Unit 1126
COMPRESSOR 1129
Removal And Installation 1129
Oil 1131
Oil Check 1132
CONDENSER 1135
Removal And Installation 1135
RECEIVER / DRIER 1137
Receiver / Drier Removal And Installation 1137
Pressure Switch Removal And Installation 1139
Schrader® Valve Removal And Installation 1140
EVAPORATOR / HEATER UNIT 1141
Removal And Installation 1141
THERMOSTAT 1143
Description 1143
Removal And Installation 1144
EXPANSION VALVE 1145
Removal And Installation 1145
EVAPORATOR COIL 1147
Removal And Installation 1147
HEATER COIL 1149
Removal And Installation 1149
BLOWER FAN 1151
Removal And Installation 1151
Disassembly And Assembly 1151
HEATER VALVE 1155
Removal And Installation 1155
EVAPORATOR / HEATER COVER 1157
Removing 1157
Installing 1157
SPECIFICATIONS 1159
LOADER SPECIFICATIONS 1161
Machine Dimensions 1161
Performance 1162
Engine 1162
Drive System 1163
Controls 1163
Hydraulic System 1164
Electrical System 1165
Capacities 1165
Tires 1166
TECHINCAL SERVICE GUIDE SPECIFICATIONS 1167
Engine 1167
Engine Torques 1167
Cooling System 1167
Loader Torques 1168
Hydraulic / Hydrostatic System 1168
Fuel Consumption 1168
TORQUE SPECIFICATIONS FOR BOLTS 1169
Torque For General SAE Bolts 1169
Torque For General Metric Bolts 1170
HYDRAULIC CONNECTION SPECIFICATIONS 1171
Straight Thread O-ring Fitting 1171
Flare Fitting 1172
Tubelines And Hoses 1172
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 1173
Specifications 1173
CONVERSIONS 1175
Decimal And Millimeter Equivalent Chart 1175
U S To Metric Conversion Chart 1175
SERVICE TOOLS REQUIRED 1177
Remote Start Tools 1177
Hydraulic Tools 1178
Mainframe And Drive Tools 1181
Electrical Tools 1184
Engine Tools 1185
HVAC Tools 1190
ALPHABETICAL INDEX 1191

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