Bobcat S630 Skid-Steer Loader Service Manual 6987160 – PDF DOWNLOAD

Description

Bobcat S630 Skid-Steer Loader Service Manual 6987160 – PDF DOWNLOAD

FILE DETAILS:

Bobcat S630 Skid-Steer Loader Service Manual 6987160 – PDF DOWNLOAD

Language : English
Pages : 1307
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S630 Skid-Steer Loader Service Manual 6987160 – PDF DOWNLOAD

S/N A3NT11001 & Above
S/N A3NU11001 & 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 S630 Skid-Steer Loader Service Manual 6987160 – 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 & MAINTENANCE 19
LIFTING AND BLOCKING THE LOADER 23
Procedure 23
LIFT ARM SUPPORT DEVICE 25
Installing 25
Removing 27
OPERATOR CAB 29
Description 29
Raising 30
Lowering 31
Cab Door Sensor 32
Special Applications Kit 33
Special Applications Kit Inspection And Maintenance 33
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
AIR CLEANER SERVICE 55
Replacing Filter Elements 55
ENGINE COOLING SYSTEM 57
Maintenance Platform 57
Cooling System Identification 57
Cleaning (Earlier Models) 58
Cleaning (Later Models) 59
Checking Level 61
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 65
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
Hydraulic / Hydrostatic Filter Identification 74
Removing And Replacing Hydraulic / Hydrostatic Filter (Hex Head Filter Cap) 75
Removing And Replacing Hydraulic / Hydrostatic Filter (Square Head Filter Cap) 76
Removing And Replacing Hydraulic / Hydrostatic Filter (Bolt-on Filter Cap) 77
Removing And Replacing Hydraulic Charge Filter 78
Breather Cap 80
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
SPARK ARRESTER MUFFLER 93
Cleaning Procedure 93
PIVOT PINS 95
Inspection And Maintenance 95
LOADER STORAGE AND RETURN TO SERVICE 97
Storage 97
Return To Service 97
STOPPING THE ENGINE AND LEAVING THE LOADER 99
Procedure 99
EMERGENCY EXIT 101
Rear Window Identification 101
Rear Window Removal (Latches) 101
Rear Window Removal (Rubber Cord) 101
External Access (Rear Window With Latches) 102
External Access (Rear Window With Rubber Cord) 102
Front Door 102
SEAT BELT 105
Inspection And Maintenance 105
HYDRAULIC SYSTEM 107
HYDRAULIC / HYDROSTATIC SCHEMATICS 113
HYDRAULIC SYSTEM INFORMATION 133
Glossary Of Hydraulic / Hydrostatic Symbols 133
Troubleshooting 137
CYLINDER (LIFT) 139
Testing 139
Removal And Installation 140
Parts Identification 142
Disassembly 143
Assembly 145
CYLINDER (TILT) 149
Testing 149
Removal And Installation 150
Base End Pivot Pin Removal And Installation 152
Parts Identification (Earlier Models) 153
Parts Identification (Later Models) 154
Disassembly 155
Assembly 158
CYLINDER (BOB-TACH) 161
Testing 161
Removal And Installation 162
Parts Identification 163
Disassembly 164
Assembly 165
MAIN RELIEF VALVE (EARLIER MODELS) 169
Description 169
Testing 170
Adjusting 172
Removal And Installation 173
MAIN RELIEF VALVE (LATER MODELS) 175
Description 175
Testing 176
Main Relief Valve Adjustment 178
Main Relief Valve Removal And Installation 178
Auxiliary Relief Valve Adjustment 179
Auxiliary Relief Valve Removal And Installation 180
HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS) 181
Description 181
Removal And Installation 182
Mount Bracket Removal And Installation 185
Identification Chart 186
Lift Load Check Valve Removal And Installation 187
Load Check Valve Removal And Installation (Tilt & Auxiliary) 188
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 189
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 189
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 190
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 190
Port Relief Valve Removal And Installation 191
Plug Removal And Installation 192
Rubber Boot Removal And Installation 193
End Cap Block Removal And Installation 194
Lift Spool And Detent Removal And Installation 195
Tilt Spool Removal And Installation 205
Auxiliary Spool Removal And Installation 207
Auxiliary Solenoid Removal And Installation 209
Solenoid Removal And Installation 210
Lock Valve Removal And Installation 211
Lift Arm Bypass Orifice Removal And Installation 213
Main Relief Valve Removal And Installation 213
Check Valve Removal And Installation 214
HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS) 215
Description 215
Removal And Installation 216
Mount Bracket Removal And Installation 220
Identification Chart 221
Lift Load Check Valve Removal And Installation 222
Load Check Valve Removal And Installation (Tilt And Auxiliary) 223
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 224
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 224
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 225
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 225
Port Relief Valve Removal And Installation 226
Plug Removal And Installation 228
Rubber Boot Removal And Installation 229
End Cap Block Removal And Installation 229
Lift Spool And Detent Removal And Installation 230
Tilt Spool Removal And Installation 238
Auxiliary Spool Removal And Installation 240
Auxiliary Solenoid Removal And Installation 241
Solenoid Removal And Installation 242
Lock Valve Removal And Installation 243
Lift Arm Bypass Orifice Removal And Installation 245
Main Relief Valve Removal And Installation 245
Auxiliary Relief Valve Removal And Installation 246
Check Valve Removal And Installation 246
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLIER MODELS) 249
Description 249
Removal And Installation 249
Actuator Removal And Installation (In Loader) 253
Actuator Removal And Installation (Out Of Loader) 255
Identification Chart 258
Mount Bracket Removal And Installation 259
Lift Load Check Valve Removal And Installation 259
Load Check Valve Removal And Installation (Tilt & Auxiliary) 260
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 261
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 261
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 262
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 262
Port Relief Valve Removal And Installation 263
Plug Removal And Installation 264
End Cap Block Removal And Installation 265
Lift Spool Removal And Installation 265
Tilt Spool Removal And Installation 270
Auxiliary Spool Removal And Installation 273
Auxiliary Solenoid Removal And Installation 274
Solenoid Removal And Installation 275
Lock Valve Removal And Installation 276
Lift Arm Bypass Orifice Removal And Installation 277
Main Relief Valve Removal And Installation 277
Check Valve Removal And Installation 278
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS) 279
Description 279
Removal And Installation 279
Actuator Removal And Installation (In Loader) 284
Actuator Removal And Installation (Out Of Loader) 285
Identification Chart 288
Mount Bracket Removal And Installation 289
Lift Load Check Valve Removal And Installation 289
Load Check Valve Removal And Installation (Tilt And Auxiliary) 290
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 291
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 291
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 292
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 292
Port Relief Valve Removal And Installation 293
Plug Removal And Installation 295
End Cap Block Removal And Installation 296
Lift Spool Removal And Installation 296
Lift Spool Disassembly And Assembly 298
Tilt Spool Removal And Installation 299
Auxiliary Spool Removal And Installation 301
Auxiliary Solenoid Removal And Installation 302
Solenoid Removal And Installation 303
Lock Valve Removal And Installation 304
Lift Arm Bypass Orifice Removal And Installation 306
Main Relief Valve Removal And Installation 306
Auxiliary Relief Valve Removal And Installation 307
Check Valve Removal And Installation 307
LIFT ARM BYPASS CONTROL VALVE 309
Description 309
Testing 309
Removal And Installation 310
Bracket Removal And Installation 311
Disassembly And Assembly 311
HYDRAULIC PUMP 313
Description 313
Pump Test At Quick Couplers 313
Direct Pump Test (Standard Section) 314
Direct Pump Test (Charge Section) 315
Removal And Installation 317
Hydraulic Pump Startup 319
Parts Identification 320
Disassembly And Assembly 321
HYDRAULIC PUMP (HIGH FLOW) 323
Description 323
Pump Test At Quick Couplers 323
Direct Pump Test (Standard Section) 324
Direct Pump Test (Charge Section) 325
Direct Pump Test (High Flow Section) 327
High Flow Relief Valve Adjustment 329
High Flow Relief Valve Removal And Installation 330
Solenoid Removal And Installation 331
Removal And Installation 332
Hydraulic Pump Startup 334
Parts Identification 335
Disassembly And Assembly 336
HYDRAULIC / HYDROSTATIC FILTERS 337
Description 337
Housing Removal And Installation 337
HYDRAULIC FLUID RESERVOIR 339
Description 339
Removal And Installation 339
Hydraulic Fluid Screen 340
OIL COOLER 341
Description 341
Removal And Installation 342
BUCKET POSITION VALVE 343
Description 343
Solenoid Removal And Installation 344
Solenoid Testing 345
Removal And Installation 345
Disassembly And Assembly 347
REAR AUXILIARY DIVERTER VALVE 349
Description 349
Solenoid Testing 349
Removal And Installation 350
Disassembly And Assembly 351
BOB-TACH (POWER) BLOCK 357
Description 357
Removal And Installation 357
Disassembly And Assembly (Earlier Models) 359
Disassembly And Assembly (Later Models) 363
BOB-TACH (POWER) BLOCK (S/N A3NT18077 AND A3NU12978 & ABOVE) 373
Description 373
Testing Relief Valve 374
Removal And Installation 376
Disassembly And Assembly 378
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 383
Description 383
Removal And Installation 384
Disassembly And Assembly (FFI/FI) 384
Disassembly And Assembly (FFH/FH) 386
AUTOMATIC RIDE CONTROL 389
Description 389
Removal And Installation 390
Checking The Pressure In The Accumulator 393
Adding Nitrogen To The Accumulator 395
HYDROSTATIC SYSTEM 397
HYDROSTATIC SYSTEM INFORMATION 399
Troubleshooting 399
Description 400
HYDROSTATIC DRIVE MOTOR 401
Description 401
Removal And Installation 402
Parts Identification 404
Disassembly And Assembly 405
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NT11001 – A3NT14899 AND S/N A3NV11001 – A3NV12251) 409
Description 409
Removal And Installation 409
Parts Identification 412
Disassembly 413
Assembly 419
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NT14900 & ABOVE AND S/N A3NV12252 & ABOVE) 425
Description 425
Removal And Installation 425
Parts Identification 428
Disassembly 429
Assembly 435
HYDROSTATIC MOTOR CARRIER 441
Description 441
Removal And Installation 442
Parts Identification 443
Disassembly 444
Assembly 446
HYDROSTATIC MOTOR CARRIER (SJC) 449
Description 449
Removal And Installation 450
Parts Identification 451
Disassembly 452
Assembly 455
CHARGE PRESSURE 459
Description 459
Testing 459
Sender Removal And Installation 461
Adjusting 462
HYDROSTATIC PUMP 465
Description 465
Removal And Installation 466
Hydrostatic Pump Startup 467
Replenishing / High Pressure Relief Valve Removal And Installation 468
Parts Identification (Left Half) 469
Parts Identification (Right Half) 470
Disassembly 471
Assembly 478
HYDROSTATIC PUMP (SJC) 485
Description 485
Hydraulic Controller Removal And Installation 486
Removal And Installation 488
Hydrostatic Pump Startup 489
Parts Identification 490
High Pressure Relief And Bypass Valve 491
Charge Relief Valve 492
Disassembly And Assembly 493
Mechanical Neutral Adjustment 506
Hydraulic Controller Neutral Adjustment 509
DRIVE BELT 513
Belt Adjustment 513
Stop Adjustment 513
Belt Replacement 513
Tensioner Pulley Removal And Installation 515
Tensioner Pulley Disassembly And Assembly 515
TWO-SPEED / BRAKE VALVE (S/N A3NT11001 – A3NT14889 AND S/N A3NV11001 – A3NV12251) 517
Description 517
Valve Block Removal And Installation 518
Valve Block Disassembly And Assembly 520
TWO-SPEED / BRAKE VALVE (S/N A3NT14900 & ABOVE AND S/N A3NV12252 & ABOVE) 523
Description 523
Valve Block Removal And Installation 524
Valve Block Disassembly And Assembly 526
DRAIN MANIFOLD 529
Description 529
Drain Manifold Removal And Installation 529
DRIVE SYSTEM 531
BRAKE (SINGLE SPEED) 533
Description 533
Disc Removal And Installation 533
BRAKE (TWO-SPEED) 535
Description 535
DRIVE COMPONENTS 537
Description 537
Axle Seal Removal And Installation 538
Axle, Sprocket And Bearings Removal And Installation 540
Chain Removal And Installation 544
CHAINCASE 547
Description 547
Front Cover Removal And Installation 547
Center Cover Removal And Installation 548
Rear Cover Removal And Installation 549
MAINFRAME 551
SEAT BAR 555
Description 555
Removal And Installation 555
Disassembly And Assembly 556
Compression Spring Disassembly And Assembly 557
OPERATOR CAB 559
Gas Spring Removal And Installation 559
Gas Spring Bracket Disassembly And Assembly 560
Removal And Installation 561
OPERATOR SEAT 563
Removal And Installation 563
Seat Belt Removal And Installation (Retractable) 563
Seat Belt And Bracket Removal And Installation (Standard) 564
Seat Belt Bracket Removal And Installation 564
OPERATOR SEAT (SUSPENSION) 565
Removal And Installation 565
Slide Rail Removal And Installation 565
Seat Belt Removal And Installation 566
Lower Cushion Removal 566
Lower Cushion Installation 567
Back Cushion Removal And Installation 567
Shock Removal And Installation 568
3-Point Seat Belt Removal And Installation 568
BOB-TACH (HAND LEVER) 571
Description 571
Removal And Installation 571
Lever And Wedge Disassembly And Assembly 573
Pivot Pin Bushing And Seal Removal And Installation 575
BOB-TACH (POWER) 577
Description 577
Removal And Installation 577
Lever And Wedge Disassembly And Assembly 580
Pivot Pin Bushing And Seal Removal And Installation 582
LIFT ARMS 583
Removal And Installation 583
REAR GRILLE 585
Identification 585
Lockable Handle Rear Grille 586
Clamping Knob Rear Grille 587
Slide In Rear Grille 588
REAR DOOR (TAILGATE) 591
Removal And Installation 591
Striker Removal And Installation 592
Striker Disassembly And Assembly 592
Striker (Adjusting) 592
Latch Removal And Installation (Earlier Models) 593
Latch Removal And Installation (Later Models) 594
FUEL TANK 595
Removal And Installation 595
Fuel Level Sender Removal And Installation 597
Fuel Fill Screen Removal And Installation 597
CONTROL PEDALS AND LINKAGES 599
Description 599
Pedal Removal And Installation 599
Linkage Removal And Installation 600
Pedal (Adjusting) 601
Floor Pan Removal And Installation 602
CONTROL PEDALS AND LINKAGES (ACS) 603
Description 603
Pedal Removal And Installation 603
Linkage Removal And Installation 604
Pedal (Adjusting) 604
Floor Pan Removal And Installation 605
CONTROL PANEL 607
Description 607
Removal And Installation 608
Disassembly And Assembly 609
Linkage Removal And Installation 613
Pintle Arm Disassembly And Assembly 617
Linkage Neutral (Adjusting) 618
Linkage Travel (Adjusting) 622
Shock Removal And Installation 626
CONTROL PANEL (SJC) 627
Description 627
Removal And Installation 627
CONTROL HANDLE / LEVER 629
Description 629
Lever Removal And Installation 629
Boot Removal And Installation 630
CONTROL HANDLE / LEVER (ACS) 631
Description 631
Handle Sensor Removal And Installation 631
Handle Removal And Installation 634
Handle Disassembly And Assembly 635
Lever Removal And Installation 635
Boot Removal And Installation 636
CONTROL HANDLE / LEVER (SJC) 637
Description 637
Joystick Testing 637
Joystick Removal And Installation 638
ACCESS PANEL (INSIDE) 639
Removal And Installation (Left) 639
Removal And Installation (Right) 639
ACCESS PANEL (INSIDE) (SJC) 641
Removal And Installation (Left) 641
Removal And Installation (Right) 641
WINDOW (REAR) 643
Removal And Installation 643
Disassembly And Assembly 644
WINDOW (TOP) 645
Removal And Installation 645
WINDOW (SIDE) 647
Removal And Installation 647
CAB DOOR 649
Description 649
Removal And Installation 649
Disassembly And Assembly 650
Aligning 651
Adjusting 652
Checking Operation 652
ARMREST 653
Description 653
Removal And Installation 654
Disassembly And Assembly 655
LEFT SIDE LOWER PANEL 659
Removal And Installation 659
Disassembly And Assembly 661
RIGHT SIDE LOWER PANEL 663
Removal And Installation 663
Disassembly And Assembly 664
HEADLINER 667
Removal And Installation 667
ELECTRICAL SYSTEM 669
ELECTRICAL SCHEMATICS 675
ELECTRICAL SYSTEM INFORMATION 882
Glossary Of Electrical Symbols 882
Standard Cab Harness Connectors 885
Deluxe Cab Harness Connectors 886
Mainframe Harness Connectors 887
Description 888
Troubleshooting 889
Fuse And Relay Location / Identification 890
Solenoid Testing 894
BATTERY 896
Removal And Installation 896
Battery Maintenance 897
Maintaining Battery Charge Level 897
Battery Service During Machine Storage 897
Battery Testing 898
Battery Charging 898
Using A Booster Battery (Jump Starting) 899
ALTERNATOR 900
Belt Adjustment 900
Belt Replacement 900
Charging System Inspection 902
Alternator Voltage Testing 903
Low Voltage Testing 903
High Voltage Testing 904
Removal And Installation 905
Parts Identification 907
STARTER 908
Testing 908
Removal And Installation 908
Parts Identification 909
INSTRUMENT PANELS 910
Left Panel (Earlier Models) 910
Left Panel (Later Models) 912
Display Screen 914
Right Panel (Standard Key Panel) 915
Right Panel (Keyless Start Panel) 916
Right Panel (Deluxe Instrumentation Panel) 917
Left Switch Panel 919
Right Switch Panel 919
Left Side Lower Panel 920
Right Side Lower Panel 920
Left Panel Removal And Installation 921
Right Panel (Standard Key Panel) Removal And Installation 921
Right Panel (Keyless Start Panel) Removal And Installation 922
Right Panel (Deluxe Instrumentation Panel) Removal And Installation 922
Key Switch Disassembly And Assembly 923
Alarm Disassembly And Assembly 923
Left Switch Panel Removal And Installation 924
Right Switch Panel Removal And Installation 924
LIGHTS 926
Front Removal And Installation 926
Rear Removal And Installation 927
Cab Light Removal And Installation 927
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY) 928
Description 928
Connector Identification 929
Removal And Installation 935
BOBCAT CONTROLLER (ACS) 938
Description 938
Connector And Wire Identification 939
Removal And Installation 940
BOBCAT CONTROLLER (SJC) (DRIVE) 942
Description 942
Connector Identification 943
Removal And Installation 945
SPEED SENSORS (SJC) 946
Description 946
Testing 946
Removal And Installation 948
DIAGNOSTIC SERVICE CODES 950
Viewing Service Codes 950
Service Codes List 951
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 958
Description 958
Inspecting The BICS™ (Engine STOPPED – Key ON) 959
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 959
Inspecting The Seat Bar Sensor (Engine RUNNING) 959
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 959
Inspecting The Lift Arm Bypass Control 959
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) 959
Troubleshooting 960
SEAT BAR SENSOR 962
Description 962
Troubleshooting 962
Testing 963
Removal And Installation 964
Bobcat Interlock Control System (BICS™) Circuit Test 967
TRACTION LOCK 970
Description 970
Troubleshooting 971
Inspecting 972
CONTROL SYSTEM (ACS) 974
Description 974
Troubleshooting 975
Handle Sensor Connector Disassembly And Assembly 976
Switch Handle Removal 977
Switch Handle Installation 979
Actuator Connector Disassembly And Assembly 982
Handle Lock Solenoid Removal And Installation 983
Handle Lock Solenoid Disassembly And Assembly 983
Foot Sensor Removal And Installation 984
Foot Sensor Disassembly And Assembly 985
Foot Sensor Lock Solenoid Removal And Installation 985
ELECTRICAL / HYDRAULIC CONTROLS 986
Identification Chart 986
Description 987
Identification Chart ACD Group 0 988
Identification Chart ACD Group 1 989
Identification Chart ACD Group 2 990
Identification Chart ACD Group 3 991
ELECTRICAL / HYDRAULIC CONTROLS (ACS) 992
Identification Chart 992
Description 993
Identification Chart ACD Group 0 994
Identification Chart ACD Group 1 995
Identification Chart ACD Group 2 996
Identification Chart ACD Group 3 997
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 998
Identification Chart 998
Description 999
Identification Chart ACD Group 0 1000
Identification Chart ACD Group 1 1001
Identification Chart ACD Group 2 1002
Identification Chart ACD Group 3 1003
SERVICE PC (LAPTOP COMPUTER) 1004
Connecting Remote Start Tool 1004
Connecting Remote Start Tool (Service Tool) 1004
CALIBRATION 1006
Description 1006
Actuator Testing 1006
Lift And Tilt Calibration (SJC) 1009
Hydrostatic Pump Calibration (SJC) 1011
Lift And Tilt Calibration (ACS) 1016
STEERING DRIFT COMPENSATION (OPERATOR MODE) 1018
Description 1018
Operation 1018
STEERING DRIFT COMPENSATION (SERVICE MODE) 1020
Description 1020
Operation 1020
FLYWHEEL RPM SENSOR 1022
Description 1022
Removal And Installation 1023
CONTROL PANEL SETUP 1024
Right Panel Setup (Deluxe Instrumentation Panel) 1024
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 1028
Password Description 1028
Changing The Owner Password 1028
Changing The User Passwords 1029
Password Lockout Feature 1029
PASSWORD SETUP (KEYLESS START PANEL) 1030
Password Description 1030
Changing The Owner Password 1030
Password Lockout Feature 1030
MAINTENANCE CLOCK 1032
Description 1032
Setup 1033
Reset 1036
BACK-UP ALARM SYSTEM 1038
Description 1038
Inspecting 1038
Adjusting Switch Position 1039
Troubleshooting (Standard And ACS) 1040
Troubleshooting (Joystick) 1041
Alarm Removal And Installation 1042
Switch Removal And Installation 1042
FRONT HORN 1044
Removal And Installation 1044
Troubleshooting 1045
Troubleshooting (Joystick) 1046
BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS 1048
Description 1048
Removal And Installation 1048
Procedure 1049
ENGINE SERVICE 1050
ENGINE INFORMATION 1054
Description 1054
Specifications 1055
Torque Values 1058
Troubleshooting 1058
Engine Removal And Installation 1060
Engine Mount Replacement 1067
Compression – Testing 1069
ENGINE SPEED CONTROL 1072
Removal And Installation 1072
Disassembly And Assembly 1072
Cable Removal And Installation 1073
ENGINE SPEED CONTROL (SJC) (EARLIER MODELS) 1074
Removal And Installation 1074
Disassembly And Assembly 1075
ENGINE SPEED CONTROL (SJC) (LATER MODELS) 1078
Removal And Installation 1078
Disassembly And Assembly 1079
MUFFLER 1082
Removal And Installation 1082
AIR CLEANER 1084
Housing Removal And Installation 1084
Housing Bracket Removal And Installation 1085
ENGINE COOLING SYSTEM (EARLIER MODELS) 1086
Radiator Removal And Installation 1086
Hydraulic Fan Description 1088
Fan Duct Removal And Installation 1089
Hydraulic Fan Motor Assembly Removal And Installation 1089
Hydraulic Fan Motor Removal And Installation 1090
Hydraulic Fan Motor Disassembly And Assembly 1091
Blower Housing Removal And Installation 1093
Water Pump Removal And Installation 1094
Water Pump Disassembly And Assembly 1094
Thermostat Housing Removal And Installation 1095
Thermostat – Testing 1096
ENGINE COOLING SYSTEM (LATER MODELS) 1098
Radiator / Oil Cooler Removal And Installation 1098
Hydraulic Fan Description 1101
Reversible Hydraulic Fan Description 1101
Fan Duct Removal And Installation 1101
Hydraulic Fan Motor Assembly Removal And Installation 1102
Hydraulic Fan Motor Removal And Installation 1103
Hydraulic Fan Motor Disassembly And Assembly 1105
Blower Housing Removal And Installation 1113
Water Pump Removal And Installation 1114
Water Pump Disassembly And Assembly 1114
Thermostat Housing Removal And Installation 1115
Thermostat – Testing 1116
LUBRICATION SYSTEM 1118
Oil Pan Removal And Installation 1118
Oil Pump Removal And Installation 1118
Relief Valve – Testing 1119
Oil Pump Inspection 1119
Oil Filter Cooler Removal And Installation 1121
Engine Oil Pressure – Testing 1121
FUEL SYSTEM 1122
Fuel Shutoff Solenoid – Testing 1122
Fuel Shutoff Solenoid Removal And Installation 1122
Fuel Injection Pump – Testing 1123
Fuel Injection Pump Assembly, Removal And Installation 1124
Governor Housing Disassembly And Assembly 1127
Governor Disassembly And Assembly 1129
Fuel Camshaft Removal And Installation 1131
Fuel Injection Pump Removal And Installation 1134
Fuel Injection Pump – Timing 1136
Fuel Injector Removal And Installation 1137
Fuel Injector Nozzle Pressure – Testing 1139
Nozzle Spray Condition 1140
Valve Seat Tightness 1140
CYLINDER HEAD 1142
Glow Plugs – Testing 1142
Glow Plugs Removal And Installation 1142
Valve Clearance Adjustment 1143
Valve Timing – Checking 1144
Cylinder Head Removal And Installation 1145
Cylinder Head Disassembly And Assembly 1148
Cylinder Head – Servicing 1148
Cylinder Head Top Clearance 1149
Valve Guide – Measuring 1150
Valve Guide Removal And Installation 1150
Reconditioning The Valve And Valve Seat 1151
Valve Spring 1153
Valve Tappets 1154
Rocker Arm And Shaft – Measuring 1155
Bridge Arm And Bridge Arm Shaft – Measuring 1155
Bridge Arm Shaft – Removal And Installation 1156
Push Rod Alignment – Measuring 1157
CRANKSHAFT AND PISTONS 1158
Piston And Connecting Rod Removal And Installation 1158
Piston And Connecting Rod – Servicing 1159
Cylinder Bore – Measuring 1162
Connecting Rod Alignment 1163
Crankshaft Gear Removal And Installation 1163
Crankshaft And Bearings Removal And Installation 1164
Crankshaft And Bearings – Servicing 1167
CAMSHAFT AND TIMING GEARS 1170
Timing Gearcase Cover Removal 1170
Timing Gearcase Cover Installation 1171
Timing Gears Backlash – Measuring 1174
Idler Gear And Camshaft Removal And Installation 1174
Camshaft – Servicing 1175
Idler Gear And Shaft – Servicing 1176
TURBOCHARGER 1178
Description 1178
Testing 1178
Removal And Installation 1179
FLYWHEEL AND HOUSING 1182
Flywheel Removal And Installation 1182
Ring Gear Removal And Installation 1184
Housing Removal And Installation 1184
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 1186
Description 1186
Testing 1187
Removal And Installation 1190
Disassembly And Assembly 1191
HEATING, VENTILATION, AIR CONDITIONING 1192
AIR CONDITIONING SYSTEM FLOW 1194
Description 1194
Chart 1195
Components 1196
Safety Equipment 1199
REGULAR MAINTENANCE 1200
Filters 1200
Compressor Drive Belt Adjustment 1201
Compressor Drive Belt Replacement 1201
Condenser 1201
Air Conditioning Lubrication 1201
Air Conditioning Service Chart 1202
Evaporator / Heater Coil 1203
TROUBLESHOOTING 1204
Blower Motor Does Not Operate 1204
Blower Motor Operates Normally, But Air Flow Is Insufficient 1204
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 1204
The Compressor Does Not Operate At All, Or Operates Improperly 1204
Gauge Pressure Related Troubleshooting 1205
Troubleshooting Tree 1207
Temperature / Pressure Chart 1211
Poor A/C Performance 1213
HVAC Repair And Leaks 1214
Electrical System 1215
Engine Coolant Bypassing The Heater Valve 1222
Heater Valve Not Opening Or Closing 1223
SYSTEM CHARGING AND RECLAMATION 1224
Refrigerant Identification 1224
Reclamation And Charging With Recovery / Charging Unit 1225
COMPRESSOR 1228
Removal And Installation 1228
Oil 1230
Oil Check 1231
CONDENSER (EARLIER MODELS) 1232
Removal And Installation 1232
CONDENSER (LATER MODELS) 1234
Removal And Installation 1234
RECEIVER / DRIER (EARLIER MODELS) 1236
Receiver / Drier Removal And Installation 1236
Pressure Relief Valve Removal And Installation 1237
Pressure Switch Removal And Installation 1238
Schrader® Valve Removal And Installation 1239
RECEIVER / DRIER (LATER MODELS) 1240
Receiver / Drier Removal And Installation 1240
Pressure Switch Removal And Installation 1242
Schrader® Valve Removal And Installation 1243
EVAPORATOR / HEATER UNIT 1244
Removal And Installation (Earlier Models) 1244
Removal And Installation (Later Models) 1245
THERMOSTAT 1246
Description 1246
Removal And Installation (Earlier Models) 1247
Removal And Installation (Later Models) 1248
EXPANSION VALVE 1250
Removal And Installation (Earlier Models) 1250
Removal And Installation (Later Models) 1252
EVAPORATOR COIL 1254
Removal And Installation (Earlier Models) 1254
Removal And Installation (Later Models) 1256
HEATER COIL 1258
Removal And Installation (Earlier Models) 1258
Removal And Installation (Later Models) 1260
BLOWER FAN 1262
Removal And Installation 1262
Disassembly And Assembly 1262
HEATER VALVE 1266
Removal And Installation (Earlier Models) 1266
Removal And Installation (Later Models) 1267
EVAPORATOR / HEATER COVER 1270
Removing 1270
Installing 1270
SPECIFICATIONS 1272
(S630) LOADER SPECIFICATIONS 1274
Machine Dimensions 1274
Performance 1275
Engine 1275
Drive System 1276
Controls 1276
Hydraulic System 1277
Electrical System 1278
Capacities 1278
Tires 1279
TORQUE SPECIFICATIONS FOR BOLTS 1280
Torque For General SAE Bolts 1280
Torque For General Metric Bolts 1281
HYDRAULIC CONNECTION SPECIFICATIONS 1282
Straight Thread O-ring Fitting 1282
Flare Fitting 1283
Tubelines And Hoses 1283
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 1284
Specifications 1284
CONVERSIONS 1286
Decimal And Millimeter Equivalent Chart 1286
U S To Metric Conversion Chart 1286
SERVICE TOOLS REQUIRED 1288
Remote Start Tools 1288
Hydraulic Tools 1289
Mainframe And Drive Tools 1292
Electrical Tools 1295
Engine Tools 1296
HVAC Tools 1301
ALPHABETICAL INDEX 1302

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