Bobcat S630 Skid-Steer Loader Service Manual 6990741 – PDF DOWNLOAD
FILE DETAILS:
Bobcat S630 Skid-Steer Loader Service Manual 6990741 – PDF DOWNLOAD
Language : English
Pages : 1212
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat S630 Skid-Steer Loader Service Manual 6990741 – PDF DOWNLOAD
S/N AHGL11001 & Above
S/N B2L511001 & 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 6990741 – 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
Description 25
Installing 26
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
Forestry Door And Window Kit 34
Forestry Door And Window Kit Inspection And Maintenance 34
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
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
Hydraulic / Hydrostatic Filter Identification 74
Removing And Replacing Hydraulic / Hydrostatic Filter (Earlier Models) 75
Removing And Replacing Hydraulic / Hydrostatic Filter (Later Models) 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 101
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 136
Disassembly 137
Assembly 139
CYLINDER (TILT) 143
Testing 143
Removal And Installation 144
Base End Pivot Pin Removal And Installation 146
Parts Identification (Earlier Models) 147
Parts Identification (Later Models) 148
Disassembly 149
Assembly 152
CYLINDER (BOB-TACH) 155
Testing 155
Removal And Installation 156
Parts Identification 157
Disassembly 158
Assembly 159
MAIN RELIEF VALVE 163
Description 163
Testing 164
Main Relief Valve Adjustment 166
Main Relief Valve Removal And Installation 166
Auxiliary Relief Valve Adjustment 167
Auxiliary Relief Valve Removal And Installation 168
HYDRAULIC CONTROL VALVE (STANDARD) 169
Description 169
Removal And Installation 170
Mount Bracket Removal And Installation 174
Identification Chart 175
Lift Load Check Valve Removal And Installation 176
Load Check Valve Removal And Installation (Tilt And Auxiliary) 177
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 178
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 178
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 179
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 179
Port Relief Valve Removal And Installation 180
Plug Removal And Installation 182
Rubber Boot Removal And Installation 183
End Cap Block Removal And Installation 183
Lift Spool And Detent Removal 184
Lift Spool And Detent Disassembly 186
Lift Spool And Detent Assembly 188
Lift Spool And Detent Installation 190
Tilt Spool Removal And Installation 192
Tilt Spool Disassembly And Assembly 193
Auxiliary Spool Removal And Installation 194
Auxiliary Solenoid Removal And Installation 195
Solenoid Removal And Installation 196
Lock Valve Removal And Installation 197
Lift Arm Bypass Orifice Removal And Installation 199
Main Relief Valve Removal And Installation 199
Auxiliary Relief Valve Removal And Installation 200
Check Valve Removal And Installation 200
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 203
Description 203
Removal And Installation 203
Actuator Removal And Installation (In Loader) 208
Actuator Removal And Installation (Out Of Loader) 209
Identification Chart 212
Mount Bracket Removal And Installation 213
Lift Load Check Valve Removal And Installation 213
Load Check Valve Removal And Installation (Tilt And Auxiliary) 214
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 215
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 215
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 216
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 216
Port Relief Valve Removal And Installation 217
Plug Removal And Installation 219
End Cap Block Removal And Installation 220
Lift Spool Removal And Installation 220
Lift Spool Disassembly And Assembly 222
Tilt Spool Removal And Installation 223
Tilt Spool Disassembly And Assembly 224
Auxiliary Spool Removal And Installation 225
Auxiliary Solenoid Removal And Installation 226
Solenoid Removal And Installation 227
Lock Valve Removal And Installation 228
Lift Arm Bypass Orifice Removal And Installation 230
Main Relief Valve Removal And Installation 230
Auxiliary Relief Valve Removal And Installation 231
Check Valve Removal And Installation 231
LIFT ARM BYPASS CONTROL VALVE 233
Description 233
Removal And Installation 234
Bracket Removal And Installation 235
Disassembly And Assembly 235
HYDRAULIC PUMP 237
Description 237
Pump Test At Quick Couplers 237
Direct Pump Test (Standard Section) 238
Direct Pump Test (Charge Section) 240
Removal And Installation 242
Hydraulic Pump Startup 244
Parts Identification 245
Disassembly And Assembly 246
HYDRAULIC PUMP (HIGH FLOW) 247
Description 247
Pump Test At Quick Couplers 247
Direct Pump Test (Standard Section) 248
Direct Pump Test (Charge Section) 249
Direct Pump Test (High Flow Section) 251
High Flow Relief Valve Adjustment 253
High Flow Relief Valve Removal And Installation 254
Solenoid Removal And Installation 255
Removal And Installation 256
Hydraulic Pump Startup 258
Parts Identification 259
Disassembly And Assembly 260
HYDRAULIC / HYDROSTATIC FILTERS (EARLIER MODELS) 261
Description 261
Housing Removal And Installation 261
HYDRAULIC / HYDROSTATIC FILTERS (LATER MODELS) 263
Description 263
Housing Removal And Installation 263
HYDRAULIC FLUID RESERVOIR 265
Description 265
Removal And Installation 265
Hydraulic Fluid Screen 266
OIL COOLER 267
Description 267
Removal And Installation 267
BUCKET POSITION VALVE 269
Description 269
Solenoid Removal And Installation 269
Solenoid Testing 270
Removal And Installation 271
Disassembly And Assembly 274
REAR AUXILIARY DIVERTER VALVE 275
Description 275
Solenoid Testing 275
Removal And Installation 276
Disassembly And Assembly 277
BOB-TACH (POWER) BLOCK (S/N AHGL11001 – AHGL11876) 283
Description 283
Removal And Installation 283
Disassembly And Assembly 285
BOB-TACH (POWER) BLOCK (S/N AHGL11877 & ABOVE) 295
Description 295
Testing Relief Valve 296
Removal And Installation 298
Disassembly And Assembly 300
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 305
Description 305
Removal And Installation 306
Disassembly And Assembly (FFI/FI) 306
Disassembly And Assembly (FFH/FH) 308
AUTOMATIC RIDE CONTROL 311
Description 311
Removal And Installation 312
Checking The Pressure In The Accumulator 315
Adding Nitrogen To The Accumulator 317
HYDROSTATIC SYSTEM 319
HYDROSTATIC SYSTEM INFORMATION 321
Troubleshooting 321
Description 322
HYDROSTATIC DRIVE MOTOR 323
Description 323
Removal And Installation 324
Parts Identification 326
Disassembly And Assembly 327
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 331
Description 331
Removal And Installation 331
Parts Identification 334
Disassembly 335
Assembly 341
HYDROSTATIC MOTOR CARRIER 347
Description 347
Removal And Installation 348
Parts Identification 349
Disassembly 350
Assembly 352
HYDROSTATIC MOTOR CARRIER (SJC) 355
Description 355
Removal And Installation 356
Parts Identification 358
Disassembly 359
Assembly 361
CHARGE PRESSURE 363
Description 363
Testing 363
Sender Removal And Installation (Earlier Models) 365
Sender Removal And Installation (Later Models) 365
Adjusting 366
HYDROSTATIC PUMP 369
Description 369
Removal And Installation 370
Hydrostatic Pump Startup 371
Replenishing / High Pressure Relief Valve Removal And Installation 372
Parts Identification (Left Half) 373
Parts Identification (Right Half) 374
Disassembly 375
Assembly 382
HYDROSTATIC PUMP (SJC) 389
Description 389
Hydraulic Controller Removal And Installation 390
Removal And Installation 392
Hydrostatic Pump Startup 393
Parts Identification 394
High Pressure Relief And Bypass Valve 395
Charge Relief Valve 396
Disassembly And Assembly 397
Mechanical Neutral Adjustment 411
Hydraulic Controller Neutral Adjustment 414
DRIVE BELT 417
Belt Adjustment 417
Stop Adjustment 417
Belt Replacement 418
Tensioner Pulley Removal And Installation 420
Tensioner Pulley Disassembly And Assembly 420
TWO-SPEED / BRAKE VALVE 423
Description 423
Valve Block Removal And Installation 424
Valve Block Disassembly And Assembly 426
DRAIN MANIFOLD 429
Description 429
Drain Manifold Removal And Installation 429
DRIVE SYSTEM 431
BRAKE (SINGLE SPEED) 433
Description 433
Disc Removal And Installation 433
BRAKE (TWO-SPEED) 435
Description 435
DRIVE COMPONENTS 437
Description 437
Axle Seal Removal And Installation 438
Axle, Sprocket And Bearings Removal And Installation 440
Chain Removal And Installation 444
CHAINCASE 447
Description 447
Front Cover Removal And Installation 447
Center Cover Removal And Installation 448
Rear Cover Removal And Installation 449
MAINFRAME 451
SEAT BAR 455
Description 455
Removal And Installation 455
Disassembly And Assembly 456
Compression Spring Disassembly And Assembly 457
OPERATOR CAB 459
Gas Spring Removal And Installation 459
Gas Spring Bracket Disassembly And Assembly 460
Removal And Installation 461
OPERATOR SEAT 463
Removal And Installation 463
Seat Belt Removal And Installation (Retractable) 463
Seat Belt And Bracket Removal And Installation (Standard) 464
Seat Belt Bracket Removal And Installation 464
OPERATOR SEAT (SUSPENSION) 465
Removal And Installation 465
Slide Rail Removal And Installation 465
Seat Belt Removal And Installation 466
Lower Cushion Removal 466
Lower Cushion Installation 467
Back Cushion Removal And Installation 467
Shock Removal And Installation 468
3-Point Seat Belt Removal And Installation 468
BOB-TACH (HAND LEVER) 471
Description 471
Removal And Installation 471
Lever And Wedge Disassembly And Assembly 473
Pivot Pin Bushing And Seal Removal And Installation 475
BOB-TACH (POWER) 477
Description 477
Removal And Installation 477
Lever And Wedge Disassembly And Assembly 480
Pivot Pin Bushing And Seal Removal And Installation 482
LIFT ARMS 483
Removal And Installation 483
REAR GRILLE 485
Removing 485
Installing 486
Shield Removal And Installation 487
REAR DOOR (TAILGATE) 489
Removal And Installation 489
Striker Removal And Installation 490
Striker Disassembly And Assembly 490
Striker (Adjusting) 491
Latch Removal And Installation 492
FUEL TANK 493
Removal And Installation 493
Fuel Level Sender Removal And Installation 495
Fuel Fill Screen Removal And Installation 495
CONTROL PEDALS AND LINKAGES 497
Description 497
Pedal Removal And Installation 497
Linkage Removal And Installation 498
Pedal (Adjusting) 499
Floor Pan Removal And Installation 500
CONTROL PEDALS AND LINKAGES (ACS) 501
Description 501
Pedal Removal And Installation 501
Linkage Removal And Installation 502
Pedal (Adjusting) 502
Floor Pan Removal And Installation 503
CONTROL PANEL 505
Description 505
Removal And Installation 506
Disassembly And Assembly 507
Linkage Removal And Installation 512
Pintle Arm Disassembly And Assembly 515
Linkage Neutral (Adjusting) 516
Linkage Travel (Adjusting) 520
Shock Removal And Installation 524
CONTROL PANEL (SJC) 525
Description 525
Removal And Installation 525
CONTROL HANDLE / LEVER 527
Description 527
Lever Removal And Installation 527
Boot Removal And Installation 528
CONTROL HANDLE / LEVER (ACS) 529
Description 529
Handle Sensor Removal And Installation 529
Handle Removal And Installation 532
Handle Disassembly And Assembly 533
Lever Removal And Installation 533
Boot Removal And Installation 534
CONTROL HANDLE / LEVER (SJC) 535
Description 535
Joystick Testing 535
Joystick Removal And Installation 536
ACCESS PANEL (INSIDE) 537
Removal And Installation (Left) 537
Removal And Installation (Right) 537
ACCESS PANEL (INSIDE) (SJC) 539
Removal And Installation (Left) 539
Removal And Installation (Right) 539
WINDOW (REAR) 541
Rear Window Identification 541
Removal And Installation (Latches) 541
Disassembly And Assembly (Latches) 542
Removal (Rubber Cord) 543
Installation (Rubber Cord) 544
WINDOW (TOP) 547
Removal And Installation 547
WINDOW (SIDE) 549
Removal And Installation 549
CAB DOOR 551
Description 551
Removal And Installation 551
Disassembly And Assembly 552
Aligning 553
Adjusting 554
Checking Operation 554
ARMREST 555
Description 555
Removal And Installation 556
Disassembly And Assembly 557
LEFT SIDE LOWER PANEL 561
Removal And Installation 561
Disassembly And Assembly 563
RIGHT SIDE LOWER PANEL 565
Removal And Installation 565
Disassembly And Assembly 566
HEADLINER 569
Removal And Installation 569
FAN DUCT PANELS 571
Removal And Installation 571
ELECTRICAL SYSTEM 573
ELECTRICAL SCHEMATICS 579
ELECTRICAL SYSTEM INFORMATION 785
Glossary Of Electrical Symbols 785
Standard Cab Harness Connectors 788
Deluxe Cab Harness Connectors 789
Mainframe Harness Connectors – Manual Controls 790
Mainframe Harness Connectors – SJC 791
Engine Harness Connectors 792
Description 793
Troubleshooting 794
Fuse And Relay Location / Identification 795
Solenoid Testing 800
BATTERY 801
Removal And Installation 801
Battery Maintenance 802
Maintaining Battery Charge Level 802
Battery Service During Machine Storage 802
Battery Testing 803
Battery Charging 803
Using A Booster Battery (Jump Starting) 804
ALTERNATOR 805
Belt Adjustment 805
Belt Replacement 805
Charging System Inspection 806
Alternator Voltage Testing 807
Low Voltage Testing 807
High Voltage Testing 808
Removal And Installation 809
Parts Identification 811
STARTER 813
Testing 813
Removal And Installation 813
Parts Identification 814
INSTRUMENT PANEL IDENTIFICATION 815
Left Panel 815
Display Screen 817
Right Panel (Standard Key Panel) 818
Right Panel (Keyless Start Panel) 819
Right Panel (Deluxe Instrumentation Panel) 820
Left Switch Panel 822
Right Switch Panel 822
Left Side Lower Panel 823
Right Side Lower Panel 823
Left Panel Removal And Installation 824
Right Panel (Standard Key Panel) Removal And Installation 824
Right Panel (Keyless Start Panel) Removal And Installation 825
Right Panel (Deluxe Instrumentation Panel) Removal And Installation 825
Key Switch Disassembly And Assembly 826
Alarm Disassembly And Assembly 826
Left Switch Panel Removal And Installation 827
Right Switch Panel Removal And Installation 828
LIGHTS 829
Front Removal And Installation 829
Rear Removal And Installation 830
Cab Light Removal And Installation (Earlier Models) 830
Cab Light Removal And Installation (Later Models) 831
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) 833
Description 833
Connector Identification 834
Removal And Installation 840
BOBCAT CONTROLLER (ACS) 841
Description 841
Connector And Wire Identification 842
Removal And Installation 843
BOBCAT CONTROLLER (SJC) (DRIVE) 845
Description 845
Connector Identification 846
Removal And Installation 848
ENGINE CONTROL UNIT (ECU) 849
Description 849
Cleaning 850
Removal And Installation 851
DIAGNOSTIC SERVICE CODES 853
Viewing Service Codes 853
Service Codes List 854
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 863
Description 863
Inspecting The BICS™ (Engine STOPPED – Key ON) 864
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 864
Inspecting The Seat Bar Sensor (Engine RUNNING) 864
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 864
Inspecting The Lift Arm Bypass Control 864
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) 864
Troubleshooting 865
SEAT BAR SENSOR 867
Description 867
Troubleshooting 867
Testing 868
Removal And Installation 869
Bobcat Interlock Control System (BICS™) Circuit Test 872
TRACTION LOCK 875
Description 875
Troubleshooting 876
Inspecting 877
CONTROL SYSTEM (ACS) 879
Description 879
Troubleshooting 880
Handle Sensor Connector Disassembly And Assembly 881
Switch Handle Removal 882
Switch Handle Installation 884
Actuator Connector Disassembly And Assembly 887
Handle Lock Solenoid Removal And Installation 888
Handle Lock Solenoid Disassembly And Assembly 888
Foot Sensor Removal And Installation 889
Foot Sensor Disassembly And Assembly 890
Foot Sensor Lock Solenoid Removal And Installation 890
ELECTRICAL / HYDRAULIC CONTROLS 891
Identification Chart 891
Description 892
Identification Chart ACD Group 0 893
Identification Chart ACD Group 1 894
Identification Chart ACD Group 2 895
Identification Chart ACD Group 3 896
ELECTRICAL / HYDRAULIC CONTROLS (ACS) 897
Identification Chart 897
Description 898
Identification Chart ACD Group 0 899
Identification Chart ACD Group 1 900
Identification Chart ACD Group 2 901
Identification Chart ACD Group 3 902
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 903
Identification Chart 903
Description 904
Identification Chart ACD Group 0 905
Identification Chart ACD Group 1 906
Identification Chart ACD Group 2 907
Identification Chart ACD Group 3 908
SERVICE PC (LAPTOP COMPUTER) 909
Connecting Remote Start Tool 909
Connecting Remote Start Tool (Service Tool) 909
CALIBRATION 911
Description 911
Actuator Testing 911
Lift And Tilt Calibration (SJC) 914
Hydrostatic Pump Calibration (SJC) 916
Lift And Tilt Calibration (ACS) 921
STEERING DRIFT COMPENSATION (OPERATOR MODE) 923
Description 923
Operation 923
STEERING DRIFT COMPENSATION (SERVICE MODE) 925
Description 925
Operation 925
CONTROL PANEL SETUP 927
Right Panel Setup (Deluxe Instrumentation Panel) 927
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 931
Password Description 931
Changing The Owner Password 931
Changing The User Passwords 932
Password Lockout Feature 932
PASSWORD SETUP (KEYLESS START PANEL) 933
Password Description 933
Changing The Owner Password 933
Password Lockout Feature 933
MAINTENANCE CLOCK 935
Description 935
Setup 936
Reset 939
BACK-UP ALARM SYSTEM 941
Description 941
Inspection 941
Adjusting Switch Position 942
Troubleshooting (Standard And ACS) 943
Troubleshooting (Joystick) 944
Alarm Removal And Installation 945
Switch Removal And Installation 945
FRONT HORN 947
Removal And Installation 947
Troubleshooting 948
Troubleshooting (Joystick) 949
ENGINE SPEED CONTROL (HAND) 951
Removal And Installation 951
ENGINE SPEED CONTROL (FOOT) 953
Removal And Installation 953
Disassembly And Assembly 954
Foot Throttle Calibration 956
CAMSHAFT AND CRANKSHAFT POSITION SENSOR 959
Removal And Installation 959
MACHINE IQ 961
Description 961
Removal And Installation 961
Procedure 962
ENGINE SERVICE 963
ENGINE INFORMATION 967
Description 967
Specifications 968
Sensor Location 970
Torque Values 976
Troubleshooting 978
Engine Removal And Installation 980
Engine Mount Replacement 989
Compression – Testing 991
Injector Signal – Testing 993
Injector Signal – Testing (In-Line) 995
Oil Pressure Testing (At Oil Sensor On Block) 997
Oil Pressure Testing (At Turbocharger Oil Inlet) 999
DIESEL OXIDATION CATALYST (DOC) 1001
Removal And Installation 1001
AIR CLEANER 1003
Housing Removal And Installation 1003
ENGINE COOLING SYSTEM (EARLIER MODELS) 1005
Radiator / Oil Cooler Removal And Installation 1005
Hydraulic Fan Description 1008
Fan Duct Removal And Installation 1008
Hydraulic Fan Motor Assembly Removal And Installation 1009
Hydraulic Fan Motor Removal And Installation 1010
Hydraulic Fan Motor Disassembly And Assembly 1012
Blower Housing Removal And Installation 1013
Water Pump Removal And Installation 1014
Thermostat Housing Removal And Installation 1015
Thermostat – Testing 1016
ENGINE COOLING SYSTEM (LATER MODELS) 1017
Radiator / Oil Cooler Removal And Installation 1017
Hydraulic Fan Description 1020
Reversible Hydraulic Fan Description 1020
Fan Duct Removal And Installation 1021
Hydraulic Fan Motor Assembly Removal And Installation 1021
Hydraulic Fan Motor Removal And Installation 1023
Hydraulic Fan Motor Disassembly And Assembly 1025
Blower Housing Removal And Installation 1033
Water Pump Removal And Installation 1034
Thermostat Housing Removal And Installation 1035
Testing The Thermostat 1036
LUBRICATION SYSTEM 1037
Description 1037
Oil Pan Removal And Installation 1038
Oil Pump Removal And Installation 1039
Oil Pump Relief Valve Description 1040
Oil Pump Relief Valve Removal And Installation 1040
Oil Cooler Removal And Installation 1041
Oil Filter Head Removal And Installation 1042
Oil Cooler Bypass Description 1043
Oil Cooler Bypass Removal And Installation 1043
FUEL SYSTEM 1045
Description 1045
Transfer Pump / High Pressure Pump Removal And Installation 1046
Fuel Temperature Sensor Removal And Installation 1048
Fuel Cooler Removal And Installation 1049
Fuel Bypass Valve Removal And Installation 1049
Fuel Recirculation Valve Removal And Installation 1050
Fuel Rail Assembly Removal And Installation 1051
Fuel Injector Removal And Installation 1052
Injector Coding 1054
Removing Air From The Fuel System 1056
CYLINDER HEAD 1059
Glow Plugs Testing 1059
Glow Plug Removal And Installation 1060
Valve Clearance Adjustment 1061
Cylinder Head Removal And Installation 1063
Cylinder Head Disassembly And Assembly 1067
Cylinder Head Inspection 1068
Cylinder Head Top Clearance 1069
Valve Step Height 1070
Valve Stem Height 1070
Valve Guide 1071
Valve 1071
Valve Spring 1072
Rocker Arm Shaft Disassembly And Assembly 1073
Rocker Arm Shaft Inspection 1074
Push Rod Inspection 1074
CRANKSHAFT AND PISTONS 1075
Piston And Connecting Rod Removal And Installation 1075
Piston And Connecting Rod Inspection 1076
Crankshaft Removal And Installation 1078
Cylinder Block Inspection 1081
Crankshaft Inspection 1083
Connecting Rod Inspection 1083
Engine Component Class 1084
CAMSHAFT 1087
Removal And Installation 1087
Inspecting 1088
GEARCASE 1091
Gearcase Cover Removal And Installation 1091
Gear Backlash 1092
Gear Timing 1093
Idle Gear Removal And Installation 1094
Idle Gear Inspection 1094
TURBOCHARGER 1095
Description 1095
Removal And Installation 1096
Inspection 1098
FLYWHEEL AND HOUSING 1099
Flywheel Removal And Installation 1099
Ring Gear Removal And Installation 1100
Housing Removal And Installation 1100
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 1101
Description 1101
Removal And Installation 1102
Disassembly And Assembly 1106
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1109
AIR CONDITIONING SYSTEM FLOW 1111
Description 1111
Chart 1112
Components 1113
Safety Equipment 1116
REGULAR MAINTENANCE 1117
Filters 1117
Belt Adjustment 1118
Belt Replacement 1118
Condenser 1118
Air Conditioning Lubrication 1118
Air Conditioning Service Chart 1119
Evaporator / Heater Coil 1120
TROUBLESHOOTING 1123
Blower Motor Does Not Operate 1123
Blower Motor Operates Normally, But Air Flow Is Insufficient 1123
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 1123
The Compressor Does Not Operate At All, Or Operates Improperly 1123
Gauge Pressure Related Troubleshooting 1124
Troubleshooting Tree 1126
Temperature / Pressure Chart 1130
Poor A/C Performance 1132
HVAC Repair And Leaks 1133
Electrical System 1134
Engine Coolant Bypassing The Heater Valve 1140
Heater Valve Not Opening Or Closing 1141
SYSTEM CHARGING AND RECLAMATION 1143
Refrigerant Identification 1143
Reclamation And Charging With Recovery / Charging Unit 1144
COMPRESSOR 1147
Removal And Installation 1147
Oil 1148
Oil Check 1149
CONDENSER 1151
Removal And Installation 1151
RECEIVER / DRIER 1153
Receiver / Drier Removal And Installation 1153
Pressure Switch Removal And Installation 1155
Schrader® Valve Removal And Installation 1156
EVAPORATOR / HEATER UNIT 1157
Removal And Installation 1157
THERMOSTAT 1159
Description 1159
Removal And Installation 1160
EXPANSION VALVE 1161
Removal And Installation 1161
EVAPORATOR COIL 1163
Removal And Installation 1163
HEATER COIL 1165
Removal And Installation 1165
BLOWER FAN 1167
Removal And Installation 1167
Disassembly And Assembly 1167
HEATER VALVE 1171
Removal And Installation 1171
EVAPORATOR / HEATER COVER 1173
Removing 1173
Installing 1173
SPECIFICATIONS 1175
(S630) LOADER SPECIFICATIONS 1177
Machine Dimensions 1177
Performance 1178
Engine 1178
Drive System 1179
Controls 1179
Hydraulic System 1180
Electrical System 1181
Capacities 1181
Tires 1182
TECHINCAL SERVICE GUIDE SPECIFICATIONS 1183
Engine 1183
Engine Torques 1183
Cooling System 1183
Loader Torques 1184
Hydraulic / Hydrostatic System 1184
Fuel Consumption 1184
TORQUE SPECIFICATIONS FOR BOLTS 1185
Torque For General SAE Bolts 1185
Torque For General Metric Bolts 1186
HYDRAULIC CONNECTION SPECIFICATIONS 1187
Straight Thread O-ring Fitting 1187
Flare Fitting 1188
Tubelines And Hoses 1188
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 1189
Specifications 1189
CONVERSIONS 1191
Decimal And Millimeter Equivalent Chart 1191
U S To Metric Conversion Chart 1191
SERVICE TOOLS REQUIRED 1193
Remote Start Tools 1193
Hydraulic Tools 1194
Mainframe And Drive Tools 1197
Electrical Tools 1200
Engine Tools 1201
HVAC Tools 1206
ALPHABETICAL INDEX 1207
IMAGES PREVIEW OF THE MANUAL:
VIDEO PREVIEW OF THE MANUAL:
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]
S.V