Bobcat S650 Skid-Steer Loader Service Manual 6987168 – PDF DOWNLOAD

Description

Bobcat S650 Skid-Steer Loader Service Manual 6987168 – PDF DOWNLOAD

FILE DETAILS:

Bobcat S650 Skid-Steer Loader Service Manual 6987168 – PDF DOWNLOAD

Language : English
Pages : 1311
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S650 Skid-Steer Loader Service Manual 6987168 – PDF DOWNLOAD

S/N A3NV11001 & Above
S/N A3NW11001 & Above
S/N 1MLS11001 & 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 S650 Skid-Steer Loader Service Manual 6987168 – 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 26
OPERATOR CAB 27
Description 27
Raising 28
Lowering 29
Cab Door Sensor 30
Special Application Kit 31
Special Applications Kit Inspection And Maintenance 31
Forestry Door And Window Kit 32
Forestry Door And Window Kit Inspection And Maintenance 32
TRANSPORTING THE LOADER ON A TRAILER 33
Loading And Unloading 33
Fastening 33
TOWING THE LOADER 35
Procedure 35
REMOTE START TOOL KIT – MEL1563 37
Remote Start Tool – MEL1563 37
Service Tool Harness Communicator – MEL1566 39
Remote Start Procedure 39
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666 43
Description 43
Remote Start Tool (Service Tool) – 7022042 44
Loader Service Tool Harness – 6689747 45
Computer Service Tool Harness – 6689746 46
Remote Start Procedure 47
SERVICE SCHEDULE 51
Maintenance Intervals 51
AIR CLEANER SERVICE 53
Replacing Filter Elements 53
ENGINE COOLING SYSTEM 55
Maintenance Platform 55
Cooling System Identification 55
Cleaning (Earlier Models) 56
Cleaning (Later Models) 58
Checking Level 60
Removing And Replacing Coolant 60
FUEL SYSTEM 61
Fuel Specifications 61
Biodiesel Blend Fuel 61
Filling The Fuel Tank 62
Fuel Filter 63
Removing Air From The Fuel System 63
ENGINE LUBRICATION SYSTEM 65
Checking And Adding Engine Oil 65
Engine Oil Chart 65
Removing And Replacing Oil And Filter 66
HYDRAULIC / HYDROSTATIC SYSTEM 69
Checking And Adding Fluid 69
Hydraulic / Hydrostatic Fluid Chart 69
Removing And Replacing Hydraulic Fluid 70
Hydraulic / Hydrostatic Filter Identification 72
Removing And Replacing Hydraulic / Hydrostatic Filter (Hex Head Filter Cap) 73
Removing And Replacing Hydraulic / Hydrostatic Filter (Square Head Filter Cap) 74
Removing And Replacing Hydraulic / Hydrostatic Filter (Bolt-on Filter Cap) 75
Removing And Replacing Hydraulic Charge Filter 76
Breather Cap 78
FINAL DRIVE TRANSMISSION (CHAINCASE) 79
Checking And Adding Fluid 79
Removing And Replacing Fluid 80
BOB-TACH (HAND LEVER) 81
Inspection And Maintenance 81
BOB-TACH (POWER) 83
Inspection And Maintenance 83
LUBRICATING THE LOADER 85
Lubrication Locations 85
TIRE MAINTENANCE 89
Wheel Nuts 89
Rotating 89
Mounting 90
SPARK ARRESTER MUFFLER 91
Cleaning Procedure 91
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 131
Glossary Of Hydraulic / Hydrostatic Symbols 131
Troubleshooting 135
CYLINDER (LIFT) 137
Testing 137
Removal And Installation 138
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 157
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 And 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 And 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 272
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) 283
Actuator Removal And Installation (Out Of Loader) 284
Identification Chart 287
Mount Bracket Removal And Installation 288
Lift Load Check Valve Removal And Installation 288
Load Check Valve Removal And Installation (Tilt And Auxiliary) 289
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 290
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 290
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 291
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 291
Port Relief Valve Removal And Installation 292
Plug Removal And Installation 294
End Cap Block Removal And Installation 295
Lift Spool Removal And Installation 295
Lift Spool Disassembly And Assembly 297
Tilt Spool Removal And Installation 298
Auxiliary Spool Removal And Installation 300
Auxiliary Solenoid Removal And Installation 301
Solenoid Removal And Installation 302
Lock Valve Removal And Installation 303
Lift Arm Bypass Orifice Removal And Installation 305
Main Relief Valve Removal And Installation 305
Auxiliary Relief Valve Removal And Installation 306
Check Valve Removal And Installation 306
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) 316
Removal And Installation 318
Hydraulic Pump Startup 320
Parts Identification 321
Disassembly And Assembly 322
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 341
BUCKET POSITION VALVE 343
Description 343
Solenoid Removal And Installation 343
Solenoid Testing 344
Removal And Installation 344
Disassembly And Assembly 346
REAR AUXILIARY DIVERTER VALVE 347
Description 347
Solenoid Testing 347
Removal And Installation 348
Disassembly And Assembly 349
BOB-TACH (POWER) BLOCK 355
Description 355
Removal And Installation 355
Disassembly And Assembly (Earlier Models) 357
Disassembly And Assembly (Later Models) 361
BOB-TACH (POWER) BLOCK (S/N A3NV25242 AND A3NW13834 & ABOVE) 369
Description 369
Testing Relief Valve 370
Removal And Installation 372
Disassembly And Assembly 374
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 379
Description 379
Removal And Installation 380
Disassembly And Assembly (FFI/FI) 380
Disassembly And Assembly (FFH/FH) 382
AUTOMATIC RIDE CONTROL 385
Description 385
Removal And Installation 386
Checking The Pressure In The Accumulator 389
Adding Nitrogen To The Accumulator 391
HYDROSTATIC SYSTEM 393
HYDROSTATIC SYSTEM INFORMATION 395
Description 395
Troubleshooting 396
HYDROSTATIC DRIVE MOTOR 397
Description 397
Removal And Installation 398
Parts Identification 400
Disassembly And Assembly 401
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV11001 – A3NV17774 AND S/N A3NW11001 – A3NW12724) 405
Description 405
Removal And Installation 405
Parts Identification 408
Disassembly 409
Assembly 415
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3NV17775 & ABOVE AND S/N A3NW12725 & ABOVE) 421
Description 421
Removal And Installation 421
Parts Identification 424
Disassembly 425
Assembly 431
HYDROSTATIC MOTOR CARRIER 437
Description 437
Removal And Installation 438
Parts Identification 439
Disassembly 440
Assembly 442
HYDROSTATIC MOTOR CARRIER (SJC) 445
Description 445
Removal And Installation 446
Parts Identification 447
Disassembly 448
Assembly 451
CHARGE PRESSURE 455
Description 455
Testing 455
Sender Removal And Installation 457
Adjusting 458
HYDROSTATIC PUMP 461
Description 461
Removal And Installation 462
Hydrostatic Pump Startup 463
Replenishing / High Pressure Relief Valve Removal And Installation 464
Parts Identification (Left Half) 465
Parts Identification (Right Half) 466
Disassembly 467
Assembly 474
HYDROSTATIC PUMP (SJC) 481
Description 481
Hydraulic Controller Removal And Installation 482
Removal And Installation 484
Hydrostatic Pump Startup 486
Parts Identification 487
High Pressure Relief And Bypass Valve 488
Charge Relief Valve 489
Disassembly And Assembly 490
Mechanical Neutral Adjustment 503
Hydraulic Controller Neutral Adjustment 506
DRIVE BELT 509
Belt Adjustment 509
Stop Adjustment 509
Belt Replacement 509
Tensioner Pulley Removal And Installation 512
Tensioner Pulley Disassembly And Assembly 513
TWO-SPEED / BRAKE VALVE (S/N A3NV11001 – A3NV17774 AND S/N A3NW11001 – A3NW12724) 515
Description 515
Valve Block Removal And Installation 516
Valve Block Disassembly And Assembly 518
TWO-SPEED / BRAKE VALVE (S/N A3NV17775 & ABOVE AND A3NW12725 & ABOVE) 521
Description 521
Valve Block Removal And Installation 522
Valve Block Disassembly And Assembly 524
DRAIN MANIFOLD 527
Description 527
Drain Manifold Removal And Installation 527
DRIVE SYSTEM 529
BRAKE (SINGLE SPEED) 531
Description 531
Disc Removal And Installation 531
BRAKE (TWO-SPEED) 533
Description 533
DRIVE COMPONENTS 535
Description 535
Axle Seal Removal And Installation 536
Axle, Sprocket And Bearings Removal And Installation 538
Chain Removal And Installation 543
CHAINCASE 545
Description 545
Front Cover Removal And Installation 545
Center Cover Removal And Installation 546
Rear Cover Removal And Installation 547
MAINFRAME 549
SEAT BAR 553
Description 553
Removal And Installation 553
Disassembly And Assembly 554
Compression Spring Disassembly And Assembly 555
OPERATOR CAB 557
Gas Spring Removal And Installation 557
Gas Spring Bracket Disassembly And Assembly 558
Removal And Installation 558
OPERATOR SEAT (SUSPENSION) 561
Removal And Installation 561
Slide Rail Removal And Installation 561
Seat Belt Removal And Installation 562
Lower Cushion Removal 562
Lower Cushion Installation 563
Back Cushion Removal And Installation 563
Shock Removal And Installation 564
3-Point Seat Belt Removal And Installation 564
BOB-TACH (HAND LEVER) 567
Description 567
Removal And Installation 567
Lever And Wedge Disassembly And Assembly 569
Pivot Pin Bushing And Seal Removal And Installation 571
BOB-TACH (POWER) 573
Description 573
Removal And Installation 573
Lever And Wedge Disassembly And Assembly 576
Pivot Pin Bushing And Seal Removal And Installation 578
LIFT ARMS 579
Stabilizer Bar Removal And Installation 579
Link Removal And Installation 580
Removal And Installation 581
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 611
Pintle Arm Disassembly And Assembly 615
Linkage Neutral (Adjusting) 616
Linkage Travel (Adjusting) 620
Shock Removal And Installation 624
CONTROL PANEL (SJC) 625
Description 625
Removal And Installation 625
CONTROL HANDLE / LEVER 627
Description 627
Lever Removal And Installation 627
Boot Removal And Installation 628
CONTROL HANDLE / LEVER (ACS) 629
Description 629
Handle Sensor Removal And Installation 629
Handle Removal And Installation 632
Handle Disassembly And Assembly 633
Lever Removal And Installation 633
Boot Removal And Installation 634
CONTROL HANDLE / LEVER (SJC) 635
Description 635
Joystick Testing 635
Joystick Removal And Installation 636
ACCESS PANEL (INSIDE) 637
Removal And Installation (Left) 637
Removal And Installation (Right) 637
ACCESS PANEL (INSIDE) (SJC) 639
Removal And Installation (Left) 639
Removal And Installation (Right) 639
WINDOW (REAR) 641
Rear Window Identification 641
Removal And Installation (Latches) 641
Disassembly And Assembly (Latches) 642
Removal (Rubber Cord) 643
Installation (Rubber Cord) 644
WINDOW (TOP) 647
Removal And Installation 647
WINDOW (SIDE) 649
Removal And Installation 649
CAB DOOR 651
Description 651
Removal And Installation 651
Disassembly And Assembly 653
Aligning 654
Adjusting 655
Checking Operation 655
ARMREST 657
Description 657
Removal And Installation 658
Disassembly And Assembly 659
LEFT SIDE LOWER PANEL 663
Removal And Installation 663
Disassembly And Assembly 665
RIGHT SIDE LOWER PANEL 667
Removal And Installation 667
Disassembly And Assembly 668
HEADLINER 671
Removal And Installation 671
ELECTRICAL SYSTEM 673
ELECTRICAL SCHEMATICS 679
ELECTRICAL SYSTEM INFORMATION 886
Glossary Of Electrical Symbols 886
Standard Cab Harness Connectors 889
Deluxe Cab Harness Connectors 890
Mainframe Harness Connectors 891
Description 892
Troubleshooting 893
Fuse And Relay Location / Identification 894
Solenoid Testing 898
BATTERY 900
Removal And Installation 900
Battery Maintenance 901
Maintaining Battery Charge Level 901
Battery Service During Machine Storage 901
Battery Testing 902
Battery Charging 902
Using A Booster Battery (Jump Starting) 903
ALTERNATOR 904
Belt Adjustment 904
Belt Replacement 904
Charging System Inspection 906
Alternator Voltage Testing 907
Low Voltage Testing 907
High Voltage Testing 908
Removal And Installation 909
Parts Identification 911
STARTER 912
Testing 912
Removal And Installation 912
Parts Identification 913
INSTRUMENT PANELS 914
Left Panel (Earlier Models) 914
Left Panel (Later Models) 916
Display Screen 918
Right Panel (Standard Key Panel) 919
Right Panel (Keyless Start Panel) 920
Right Panel (Deluxe Instrumentation Panel) 921
Left Side Lower Panel 924
Right Side Lower Panel 924
Left Panel Removal And Installation 925
Right Panel (Standard Key Panel) Removal And Installation 925
Right Panel (Keyless Start Panel) Removal And Installation 926
Right Panel (Deluxe Instrumentation Panel) Removal And Installation 926
Key Switch Disassembly And Assembly 927
Alarm Disassembly And Assembly 927
Left Switch Panel Removal And Installation 928
Right Switch Panel Removal And Installation 928
LIGHTS 930
Front Removal And Installation 930
Rear Removal And Installation 931
Cab Light Removal And Installation (Earlier Models) 931
Cab Light Removal And Installation (Later Models) 932
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY) 934
Description 934
Connector Identification 935
Removal And Installation 941
BOBCAT CONTROLLER (ACS) 944
Description 944
Connector And Wire Identification 945
Removal And Installation 946
BOBCAT CONTROLLER (SJC) (DRIVE) 948
Description 948
Connector Identification 949
Removal And Installation 951
SPEED SENSORS (SJC) 952
Description 952
Testing 952
Removal And Installation 954
DIAGNOSTIC SERVICE CODES 956
Viewing Service Codes 956
Service Codes List 957
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 964
Description 964
Inspecting The BICS™ (Engine STOPPED – Key ON) 965
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 965
Inspecting The Seat Bar Sensor (Engine RUNNING) 965
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 965
Inspecting The Lift Arm Bypass Control 965
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) 965
Troubleshooting 966
SEAT BAR SENSOR 968
Description 968
Troubleshooting 968
Testing 969
Removal And Installation 970
Bobcat Interlock Control System (BICS™) Circuit Test 973
TRACTION LOCK 976
Description 976
Troubleshooting 977
Inspecting 978
CONTROL SYSTEM (ACS) 980
Description 980
Troubleshooting 980
Handle Sensor Connector Disassembly And Assembly 981
Switch Handle Removal 982
Switch Handle Installation 985
Actuator Connector Disassembly And Assembly 988
Handle Lock Solenoid Removal And Installation 988
Handle Lock Solenoid Disassembly And Assembly 989
Foot Sensor Removal And Installation 990
Foot Sensor Disassembly And Assembly 991
Foot Sensor Lock Solenoid Removal And Installation 991
ELECTRICAL / HYDRAULIC CONTROLS 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 (ACS) 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
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 1004
Identification Chart 1004
Description 1005
Identification Chart ACD Group 0 1006
Identification Chart ACD Group 1 1007
Identification Chart ACD Group 2 1008
Identification Chart ACD Group 3 1009
SERVICE PC (LAPTOP COMPUTER) 1010
Connecting Remote Start Tool 1010
Connecting Remote Start Tool (Service Tool) 1010
CALIBRATION 1012
Description 1012
Actuator Testing 1012
Lift And Tilt Calibration (SJC) 1015
Hydrostatic Pump Calibration (SJC) 1017
Lift And Tilt Calibration (ACS) 1022
STEERING DRIFT COMPENSATION (OPERATOR MODE) 1024
Description 1024
Operation 1024
STEERING DRIFT COMPENSATION (SERVICE MODE) 1026
Description 1026
Operation 1026
FLYWHEEL RPM SENSOR 1028
Description 1028
Removal And Installation 1029
CONTROL PANEL SETUP 1030
Right Panel Setup (Deluxe Instrumentation Panel) 1030
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 1034
Password Description 1034
Changing The Owner Password 1034
Changing The User Passwords 1035
Password Lockout Feature 1035
PASSWORD SETUP (KEYLESS START PANEL) 1036
Password Description 1036
Changing The Owner Password 1036
Password Lockout Feature 1036
MAINTENANCE CLOCK 1038
Description 1038
Setup 1038
Reset 1042
BACK-UP ALARM SYSTEM 1044
Description 1044
Inspecting 1044
Adjusting Switch Position 1045
Troubleshooting (Standard And ACS) 1046
Troubleshooting (Joystick) 1047
Alarm Removal And Installation 1048
Switch Removal And Installation 1048
FRONT HORN 1050
Removal And Installation 1050
Troubleshooting 1051
Troubleshooting (Joystick) 1052
ENGINE SERVICE 1054
ENGINE INFORMATION 1058
Description 1058
Specifications 1059
Torque Values 1062
Troubleshooting 1062
Engine Removal And Installation 1064
Engine Mount Replacement 1071
Compression – Testing 1072
ENGINE SPEED CONTROL 1076
Removal And Installation 1076
Disassembly And Assembly 1076
Cable Removal And Installation 1077
ENGINE SPEED CONTROL (SJC) (EARLIER MODELS) 1078
Removal And Installation 1078
Disassembly And Assembly 1079
ENGINE SPEED CONTROL (SJC) (LATER MODELS) 1082
Removal And Installation 1082
Disassembly And Assembly 1083
MUFFLER 1086
Removal And Installation 1086
AIR CLEANER 1088
Housing Removal And Installation 1088
Housing Bracket Removal And Installation 1089
ENGINE COOLING SYSTEM (EARLIER MODELS) 1090
Radiator Removal And Installation 1090
Hydraulic Fan Description 1092
Fan Duct Removal And Installation 1093
Hydraulic Fan Motor Assembly Removal And Installation 1093
Hydraulic Fan Motor Removal And Installation 1094
Hydraulic Fan Motor Disassembly And Assembly 1095
Blower Housing Removal And Installation 1097
Water Pump Removal And Installation 1097
Water Pump Disassembly And Assembly 1098
Thermostat Housing Removal And Installation 1099
Thermostat – Testing 1100
ENGINE COOLING SYSTEM (LATER MODELS) 1102
Radiator / Oil Cooler Removal And Installation 1102
Hydraulic Fan Description 1105
Reversible Hydraulic Fan Description 1105
Fan Duct Removal And Installation 1105
Hydraulic Fan Motor Assembly Removal And Installation 1106
Hydraulic Fan Motor Removal And Installation 1107
Hydraulic Fan Motor Disassembly And Assembly 1109
Blower Housing Removal And Installation 1117
Water Pump Removal And Installation 1117
Water Pump Disassembly And Assembly 1118
Thermostat Housing Removal And Installation 1119
Thermostat – Testing 1120
LUBRICATION SYSTEM 1122
Oil Pan Removal And Installation 1122
Oil Pump Removal And Installation 1122
Relief Valve – Testing 1123
Oil Pump Inspection 1123
Oil Filter Cooler Removal And Installation 1125
Engine Oil Pressure – Testing 1125
FUEL SYSTEM 1126
Fuel Shutoff Solenoid – Testing 1126
Fuel Shutoff Solenoid Removal And Installation 1126
Fuel Injection Pump – Testing 1127
Fuel Injection Pump Assembly Removal And Installation 1128
Governor Housing Disassembly And Assembly 1131
Governor Disassembly And Assembly 1133
Fuel Camshaft Removal And Installation 1135
Fuel Injection Pump Removal And Installation 1138
Fuel Injection Pump – Timing 1140
Fuel Injector Removal And Installation 1142
Fuel Injector Nozzle Pressure – Testing 1143
Nozzle Spray Condition 1144
Valve Seat Tightness 1144
CYLINDER HEAD 1146
Glow Plugs – Testing 1146
Glow Plugs Removal And Installation 1146
Valve Clearance Adjustment 1147
Valve Timing – Inspecting 1148
Cylinder Head Removal And Installation 1149
Cylinder Head Disassembly And Assembly 1152
Cylinder Head – Servicing 1152
Cylinder Head Top Clearance 1153
Valve Guide – Inspecting 1154
Valve Guide Removal And Installation 1154
Reconditioning The Valve And Valve Seat 1155
Valve Spring 1157
Valve Tappets 1158
Rocker Arm And Shaft – Measuring 1159
Bridge Arm And Bridge Arm Shaft – Measuring 1159
Bridge Arm Shaft – Removal And Installation 1160
Push Rod Alignment – Inspecting 1161
CRANKSHAFT AND PISTONS 1162
Piston And Connecting Rod Removal And Installation 1162
Piston And Connecting Rod – Servicing 1163
Cylinder Bore – Measuring 1166
Connecting Rod Alignment 1167
Crankshaft Gear Removal And Installation 1167
Crankshaft And Bearings Removal And Installation 1168
Crankshaft And Bearings – Servicing 1171
CAMSHAFT AND TIMING GEARS 1174
Timing Gearcase Cover Removal 1174
Timing Gearcase Cover Installation 1174
Timing Gears Backlash – Measuring 1177
Idler Gear And Camshaft Removal And Installation 1177
Camshaft – Servicing 1178
Idler Gear And Shaft – Servicing 1180
TURBOCHARGER 1182
Description 1182
Testing 1182
Removal And Installation 1183
FLYWHEEL AND HOUSING 1186
Flywheel Removal And Installation 1186
Ring Gear Removal And Installation 1188
Housing Removal And Installation 1188
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 1190
Description 1190
Testing 1191
Removal And Installation 1194
Disassembly And Assembly 1195
HEATING, VENTILATION, AIR CONDITIONING (HVAC) 1196
AIR CONDITIONING SYSTEM FLOW 1198
Description 1198
Chart 1199
Components 1200
Safety Equipment 1203
REGULAR MAINTENANCE 1204
Filters 1204
Compressor Drive Belt Adjustment 1205
Compressor Drive Belt Replacement 1205
Condenser 1205
Air Conditioning Lubrication 1205
Air Conditioning Service Chart 1206
Evaporator / Heater Coil 1207
TROUBLESHOOTING 1208
Blower Motor Does Not Operate 1208
Blower Motor Operates Normally, But Air Flow Is Insufficient 1208
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 1208
The Compressor Does Not Operate At All, Or Operates Improperly 1208
Gauge Pressure Related Troubleshooting 1209
Troubleshooting Tree 1211
Temperature / Pressure Chart 1215
Poor A/C Performance 1217
HVAC Repair And Leaks 1218
Electrical System 1219
Engine Coolant Bypassing The Heater Valve 1226
Heater Valve Not Opening Or Closing 1227
SYSTEM CHARGING AND RECLAMATION 1228
Refrigerant Identification 1228
Reclamation And Charging With Recovery / Charging Unit 1229
COMPRESSOR 1232
Removal And Installation 1232
Oil 1233
Oil Check 1234
CONDENSER (EARLIER MODELS) 1236
Removal And Installation 1236
CONDENSER (LATER MODELS) 1238
Removal And Installation 1238
RECEIVER / DRIER (EARLIER MODELS) 1240
Receiver / Drier Removal And Installation 1240
Pressure Relief Valve Removal And Installation 1241
Pressure Switch Removal And Installation 1242
Schrader® Valve Removal And Installation 1243
RECEIVER / DRIER (LATER MODELS) 1244
Receiver / Drier Removal And Installation 1244
Pressure Switch Removal And Installation 1246
Schrader® Valve Removal And Installation 1247
EVAPORATOR / HEATER UNIT 1248
Removal And Installation (Earlier Models) 1248
Removal And Installation (Later Models) 1249
THERMOSTAT 1250
Description 1250
Removal And Installation (Earlier Models) 1251
Removal And Installation (Later Models) 1252
EXPANSION VALVE 1254
Removal And Installation (Earlier Models) 1254
Removal And Installation (Later Models) 1256
EVAPORATOR COIL 1258
Removal And Installation (Earlier Models) 1258
Removal And Installation (Later Models) 1260
HEATER COIL 1262
Removal And Installation (Earlier Models) 1262
Removal And Installation (Later Models) 1264
BLOWER FAN 1266
Removal And Installation 1266
Disassembly And Assembly 1266
HEATER VALVE 1270
Removal And Installation (Earlier Models) 1270
Removal And Installation (Later Models) 1271
EVAPORATOR / HEATER COVER 1274
Removing 1274
Installing 1274
SPECIFICATIONS 1276
(S650) LOADER SPECIFICATIONS 1278
Machine Dimensions 1278
Performance 1279
Engine 1279
Drive System 1280
Controls 1280
Hydraulic System 1281
Electrical System 1282
Capacities 1282
Tires 1283
TORQUE SPECIFICATIONS FOR BOLTS 1284
Torque For General SAE Bolts 1284
Torque For General Metric Bolts 1285
HYDRAULIC CONNECTION SPECIFICATIONS 1286
Straight Thread O-ring Fitting 1286
Flare Fitting 1287
Tubelines And Hoses 1287
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 1288
Specifications 1288
CONVERSIONS 1290
Decimal And Millimeter Equivalent Chart 1290
U S To Metric Conversion Chart 1290
SERVICE TOOLS REQUIRED 1292
Remote Start Tools 1292
Hydraulic Tools 1293
Mainframe And Drive Tools 1296
Electrical Tools 1299
Engine Tools 1300
HVAC Tools 1305
ALPHABETICAL INDEX 1306

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