Bobcat S650 Skid-Steer Loader Service Manual 6990746 – PDF DOWNLOAD

Description

Bobcat S650 Skid-Steer Loader Service Manual 6990746 – PDF DOWNLOAD

FILE DETAILS:

Bobcat S650 Skid-Steer Loader Service Manual 6990746 – PDF DOWNLOAD

Language : English
Pages : 1204
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S650 Skid-Steer Loader Service Manual 6990746 – PDF DOWNLOAD

S/N ALJ811001 & Above
S/N S1ML11001 & Above
S/N B2LA11001 & 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 6990746 – 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 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 Level 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 100
SEAT BELT 103
Inspection And Maintenance 103
HYDRAULIC SYSTEM 105
HYDRAULIC / HYDROSTATIC SCHEMATICS 111
HYDRAULIC SYSTEM INFORMATION 127
Glossary Of Hydraulic / Hydrostatic Symbols 127
Troubleshooting 131
CYLINDER (LIFT) 133
Testing 133
Removal And Installation 134
Parts Identification 138
Disassembly 139
Assembly 140
CYLINDER (TILT) 143
Testing 143
Removal And Installation 144
Base End Pivot Pin Removal And Installation 145
Parts Identification (Earlier Models) 146
Parts Identification (Later Models) 147
Disassembly 148
Assembly 150
CYLINDER (BOB-TACH) 153
Testing 153
Removal And Installation 154
Parts Identification 155
Disassembly 156
Assembly 157
MAIN RELIEF VALVE 161
Description 161
Testing 162
Main Relief Valve Adjustment 164
Main Relief Valve Removal And Installation 164
Auxiliary Relief Valve Adjustment 165
Auxiliary Relief Valve Removal And Installation 166
HYDRAULIC CONTROL VALVE (STANDARD) 167
Description 167
Removal And Installation 168
Mount Bracket Removal And Installation 172
Identification Chart 173
Lift Load Check Valve Removal And Installation 174
Load Check Valve Removal And Installation (Tilt And Auxiliary) 175
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 176
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 176
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 177
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 177
Port Relief Valve Removal And Installation 178
Plug Removal And Installation 180
Rubber Boot Removal And Installation 181
End Cap Block Removal And Installation 181
Lift Spool And Detent Removal And Installation 182
Tilt Spool Removal And Installation 190
Auxiliary Spool Removal And Installation 192
Auxiliary Solenoid Removal And Installation 193
Solenoid Removal And Installation 194
Lock Valve Removal And Installation 195
Lift Arm Bypass Orifice Removal And Installation 197
Main Relief Valve Removal And Installation 197
Auxiliary Relief Valve Removal And Installation 198
Check Valve Removal And Installation 198
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 201
Description 201
Removal And Installation 201
Actuator Removal And Installation (In Loader) 206
Actuator Removal And Installation (Out Of Loader) 207
Identification Chart 210
Mount Bracket Removal And Installation 211
Lift Load Check Valve Removal And Installation 211
Load Check Valve Removal And Installation (Tilt And Auxiliary) 212
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 213
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 213
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 214
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 214
Port Relief Valve Removal And Installation 215
Plug Removal And Installation 217
End Cap Block Removal And Installation 218
Lift Spool Removal And Installation 218
Lift Spool Disassembly And Assembly 220
Tilt Spool Removal And Installation 221
Tilt Spool Disassembly And Assembly 222
Auxiliary Spool Removal And Installation 223
Auxiliary Solenoid Removal And Installation 224
Solenoid Removal And Installation 225
Lock Valve Removal And Installation 226
Lift Arm Bypass Orifice Removal And Installation 228
Main Relief Valve Removal And Installation 228
Auxiliary Relief Valve Removal And Installation 229
Check Valve Removal And Installation 229
LIFT ARM BYPASS CONTROL VALVE 231
Description 231
Removal And Installation 232
Bracket Removal And Installation 233
Disassembly And Assembly 233
HYDRAULIC PUMP 235
Description 235
Pump Test At Quick Couplers 235
Direct Pump Test (Standard Section) 236
Direct Pump Test (Charge Section) 238
Removal And Installation 240
Hydraulic Pump Startup 242
Parts Identification 243
Disassembly And Assembly 244
HYDRAULIC PUMP (HIGH FLOW) 245
Description 245
Pump Test At Quick Couplers 245
Direct Pump Test (Standard Section) 246
Direct Pump Test (Charge Section) 247
Direct Pump Test (High Flow Section) 249
High Flow Relief Valve Adjustment 251
High Flow Relief Valve Removal And Installation 252
Solenoid Removal And Installation 253
Removal And Installation 254
Hydraulic Pump Startup 256
Parts Identification 257
Disassembly And Assembly 258
HYDRAULIC / HYDROSTATIC FILTERS (EARLIER MODELS) 259
Description 259
Housing Removal And Installation 259
HYDRAULIC / HYDROSTATIC FILTERS (LATER MODELS) 261
Description 261
Housing Removal And Installation 261
HYDRAULIC FLUID RESERVOIR 263
Description 263
Removal And Installation 263
Hydraulic Fluid Screen 264
OIL COOLER 265
Description 265
Removal And Installation 265
BUCKET POSITION VALVE 267
Description 267
Solenoid Removal And Installation 267
Solenoid Testing 269
Removal And Installation 269
Disassembly And Assembly 272
REAR AUXILIARY DIVERTER VALVE 273
Description 273
Solenoid Testing 273
Removal And Installation 274
Disassembly And Assembly 276
BOB-TACH (POWER) BLOCK (S/N ALJ811001 – ALJ813901) 283
Description 283
Removal And Installation 283
Disassembly And Assembly 285
BOB-TACH (POWER) BLOCK (S/N ALJ813902 & ABOVE) 293
Description 293
Testing Relief Valve 294
Removal And Installation 296
Disassembly And Assembly 298
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 303
Description 303
Removal And Installation 304
Disassembly And Assembly (FFI/FI) 304
Disassembly And Assembly (FFH/FH) 306
AUTOMATIC RIDE CONTROL 309
Description 309
Removal And Installation 310
Checking The Pressure In The Accumulator 313
Adding Nitrogen To The Accumulator 315
HYDROSTATIC SYSTEM 317
HYDROSTATIC SYSTEM INFORMATION 319
Troubleshooting 319
Description 320
HYDROSTATIC DRIVE MOTOR 321
Description 321
Removal And Installation 322
Parts Identification 324
Disassembly And Assembly 325
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 329
Description 329
Removal And Installation 329
Parts Identification 332
Disassembly 333
Assembly 339
HYDROSTATIC MOTOR CARRIER 345
Description 345
Removal And Installation 346
Parts Identification 347
Disassembly 348
Assembly 350
HYDROSTATIC MOTOR CARRIER (SJC) 353
Description 353
Removal And Installation 354
Parts Identification 356
Disassembly 357
Assembly 359
CHARGE PRESSURE 361
Description 361
Testing 361
Sender Removal And Installation (Earlier Models) 363
Sender Removal And Installation (Later Models) 363
Adjusting 364
HYDROSTATIC PUMP 367
Description 367
Removal And Installation 368
Hydrostatic Pump Startup 369
Replenishing / High Pressure Relief Valve Removal And Installation 369
Parts Identification (Left Half) 370
Parts Identification (Right Half) 371
Disassembly 372
Assembly 379
HYDROSTATIC PUMP (SJC) 387
Description 387
Hydraulic Controller Removal And Installation 388
Removal And Installation 390
Hydrostatic Pump Startup 391
Parts Identification 392
High Pressure Relief And Bypass Valve 393
Charge Relief Valve 394
Disassembly And Assembly 395
Mechanical Neutral Adjustment 408
Hydraulic Controller Neutral Adjustment 411
DRIVE BELT 415
Belt Adjustment 415
Stop Adjustment 415
Belt Replacement 416
Tensioner Pulley Removal And Installation (Earlier Models) 418
Tensioner Pulley Disassembly And Assembly 418
Tensioner Pulley Removal And Installation (Later Models) 419
Tensioner Pulley Disassembly And Assembly 419
TWO-SPEED / BRAKE VALVE 421
Description 421
Valve Block Removal And Installation 422
Valve Block Disassembly And Assembly 424
DRAIN MANIFOLD 427
Description 427
Drain Manifold Removal And Installation 427
DRIVE SYSTEM 429
BRAKE (SINGLE SPEED) 431
Description 431
Disc Removal And Installation 431
BRAKE (TWO-SPEED) 433
Description 433
DRIVE COMPONENTS 435
Description 435
Axle Seal Removal And Installation 436
Axle, Sprocket And Bearings Removal And Installation 438
Chain Removal And Installation 441
CHAINCASE 443
Description 443
Front Cover Removal And Installation 443
Center Cover Removal And Installation 444
Rear Cover Removal And Installation 445
MAINFRAME 447
SEAT BAR 451
Description 451
Removal And Installation 451
Disassembly And Assembly 452
Compression Spring Disassembly And Assembly 453
OPERATOR CAB 455
Gas Spring Removal And Installation 455
Gas Spring Bracket Disassembly And Assembly 456
Removal And Installation 457
OPERATOR SEAT 459
Removal And Installation 459
Seat Belt Removal And Installation (Retractable) 459
Seat Belt And Bracket Removal And Installation (Standard) 460
Seat Belt Bracket Removal And Installation 460
OPERATOR SEAT (SUSPENSION) 461
Removal And Installation 461
Slide Rail Removal And Installation 461
Seat Belt Removal And Installation 462
Lower Cushion Removal 462
Lower Cushion Installation 463
Back Cushion Removal And Installation 463
Shock Removal And Installation 464
3-Point Seat Belt Removal And Installation 464
BOB-TACH (HAND LEVER) 467
Description 467
Removal And Installation 467
Lever And Wedge Disassembly And Assembly 469
Pivot Pin Bushing And Seal Removal And Installation 472
BOB-TACH (POWER) 473
Description 473
Removal And Installation 473
Lever And Wedge Disassembly And Assembly 476
Pivot Pin Bushing And Seal Removal And Installation 478
LIFT ARMS 479
Stabilizer Bar Removal And Installation 479
Link Removal And Installation 480
Removal And Installation 481
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 508
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 527
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 555
Disassembly And Assembly 556
LEFT SIDE LOWER PANEL 559
Removal And Installation 559
Disassembly And Assembly 562
RIGHT SIDE LOWER PANEL 563
Removal And Installation 563
Disassembly And Assembly 565
HEADLINER 567
Removal And Installation 567
FAN DUCT PANELS 569
Removal And Installation 569
ELECTRICAL SYSTEM 571
ELECTRICAL SCHEMATICS 577
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
Servicing 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 826
LIGHTS 827
Front Removal And Installation 827
Rear Removal And Installation 828
Cab Light Removal And Installation (Earlier Models) 828
Cab Light Removal And Installation (Later Models) 829
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) 831
Description 831
Connector Identification 832
Removal And Installation 838
BOBCAT CONTROLLER (ACS) 839
Description 839
Connector And Wire Identification 840
Removal And Installation 841
BOBCAT CONTROLLER (SJC) (DRIVE) 843
Description 843
Connector Identification 844
Removal And Installation 846
ENGINE CONTROL UNIT (ECU) 847
Description 847
Cleaning 848
Removal And Installation 849
DIAGNOSTIC SERVICE CODES 851
Viewing Service Codes 851
Service Codes List 852
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 861
Description 861
Inspecting The BICS™ (Engine STOPPED – Key ON) 862
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 862
Inspecting The Seat Bar Sensor (Engine RUNNING) 862
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 862
Inspecting The Lift Arm Bypass Control 862
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) 862
Troubleshooting 863
SEAT BAR SENSOR 865
Description 865
Troubleshooting 865
Testing 866
Removal And Installation 867
Bobcat Interlock Control System (BICS™) Circuit Test 870
TRACTION LOCK 873
Description 873
Troubleshooting 874
Inspecting 875
CONTROL SYSTEM (ACS) 877
Description 877
Troubleshooting 877
Handle Sensor Connector Disassembly And Assembly 878
Switch Handle Removal 879
Switch Handle Installation 882
Actuator Connector Disassembly And Assembly 884
Handle Lock Solenoid Removal And Installation 885
Handle Lock Solenoid Disassembly And Assembly 885
Foot Sensor Removal And Installation 886
Foot Sensor Disassembly And Assembly 887
Foot Sensor Lock Solenoid Removal And Installation 887
ELECTRICAL / HYDRAULIC CONTROLS 889
Identification Chart 889
Description 890
Identification Chart ACD Group 0 891
Identification Chart ACD Group 1 892
Identification Chart ACD Group 2 893
Identification Chart ACD Group 3 894
ELECTRICAL / HYDRAULIC CONTROLS (ACS) 895
Identification Chart 895
Description 896
Identification Chart ACD Group 0 897
Identification Chart ACD Group 1 898
Identification Chart ACD Group 2 899
Identification Chart ACD Group 3 900
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 901
Identification Chart 901
Description 902
Identification Chart ACD Group 0 903
Identification Chart ACD Group 1 904
Identification Chart ACD Group 2 905
Identification Chart ACD Group 3 906
SERVICE PC (LAPTOP COMPUTER) 907
Connecting Remote Start Tool 907
Connecting Remote Start Tool (Service Tool) 907
CALIBRATION 909
Description 909
Actuator Testing 909
Lift And Tilt Calibration (SJC) 911
Hydrostatic Pump Calibration (SJC) 913
Lift And Tilt Calibration (ACS) 918
STEERING DRIFT COMPENSATION (OPERATOR MODE) 921
Description 921
Operation 921
STEERING DRIFT COMPENSATION (SERVICE MODE) 923
Description 923
Operation 923
CONTROL PANEL SETUP 925
Right Panel Setup (Deluxe Instrumentation Panel) 925
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 929
Password Description 929
Changing The Owner Password 929
Changing The User Passwords 930
Password Lockout Feature 930
PASSWORD SETUP (KEYLESS START PANEL) 931
Password Description 931
Changing The Owner Password 931
Password Lockout Feature 931
MAINTENANCE CLOCK 933
Description 933
Setup 934
Reset 937
BACK-UP ALARM SYSTEM 939
Description 939
Inspecting 939
Adjusting Switch Position 940
Troubleshooting (Standard And ACS) 941
Troubleshooting (Joystick) 942
Alarm Removal And Installation 943
Switch Removal And Installation 943
FRONT HORN 945
Removal And Installation 945
Troubleshooting 946
Troubleshooting (Joystick) 947
ENGINE SPEED CONTROL (HAND) 949
Removal And Installation 949
ENGINE SPEED CONTROL (FOOT) 951
Removal And Installation 951
Disassembly And Assembly 952
Foot Throttle Calibration 954
CAMSHAFT AND CRANKSHAFT POSITION SENSOR 957
Removal And Installation 957
MACHINE IQ 959
Description 959
Removal And Installation 959
Procedure 960
ENGINE SERVICE 961
ENGINE INFORMATION 965
Description 965
Specifications 966
Sensor Location 968
Torque Values 974
Troubleshooting 976
Engine Removal And Installation 978
Engine Mount Replacement 987
Compression – Testing 989
Injector Signal – Testing 991
Injector Signal – Testing (In-Line) 993
Oil Pressure Testing (At Oil Sensor On Block) 995
Oil Pressure Testing (At Turbocharger Oil Inlet) 997
DIESEL OXIDATION CATALYST (DOC) 999
Removal And Installation 999
AIR CLEANER 1001
Housing Removal And Installation 1001
ENGINE COOLING SYSTEM (EARLIER MODELS) 1003
Radiator / Oil Cooler Removal And Installation 1003
Hydraulic Fan Description 1006
Fan Duct Removal And Installation 1006
Hydraulic Fan Motor Assembly Removal And Installation 1007
Hydraulic Fan Motor Removal And Installation 1008
Hydraulic Fan Motor Disassembly And Assembly 1009
Blower Housing Removal And Installation 1011
Water Pump Removal And Installation 1012
Thermostat Housing Removal And Installation 1013
Thermostat-Testing 1014
ENGINE COOLING SYSTEM (LATER MODELS) 1015
Radiator / Oil Cooler Removal And Installation 1015
Hydraulic Fan Description 1018
Reversible Hydraulic Fan Description 1018
Fan Duct Removal And Installation 1018
Hydraulic Fan Motor Assembly Removal And Installation 1019
Hydraulic Fan Motor Removal And Installation 1020
Hydraulic Fan Motor Disassembly And Assembly 1022
Blower Housing Removal And Installation 1030
Water Pump Removal And Installation 1031
Thermostat Housing Removal And Installation 1032
Thermostat-Testing 1033
LUBRICATION SYSTEM 1035
Description 1035
Oil Pan Removal And Installation 1036
Oil Pump Removal And Installation 1037
Oil Pump Relief Valve Description 1037
Oil Pump Relief Valve Removal And Installation 1037
Oil Cooler Removal And Installation 1038
Oil Filter Head Removal And Installation 1038
Oil Cooler Bypass Description 1039
Oil Cooler Bypass Removal And Installation 1039
FUEL SYSTEM 1041
Description 1041
Transfer Pump / High Pressure Pump Removal And Installation 1042
Fuel Temperature Sensor Removal And Installation 1044
Fuel Cooler Removal And Installation 1045
Fuel Bypass Valve Removal And Installation 1045
Fuel Recirculation Valve Removal And Installation 1046
Fuel Rail Assembly Removal And Installation 1047
Fuel Injector Removal And Installation 1048
Injector Coding 1050
Removing Air From The Fuel System 1052
CYLINDER HEAD 1055
Glow Plugs Testing 1055
Glow Plug Removal And Installation 1056
Valve Clearance Adjustment 1057
Cylinder Head Removal And Installation 1059
Cylinder Head Disassembly And Assembly 1063
Cylinder Head Inspection 1064
Cylinder Head Top Clearance 1065
Valve Step Height 1066
Valve Stem Height 1066
Valve Guide 1067
Valve 1067
Valve Spring 1068
Rocker Arm Shaft Disassembly And Assembly 1069
Rocker Arm Shaft Inspection 1070
Push Rod Inspection 1070
CRANKSHAFT AND PISTONS 1071
Piston And Connecting Rod Removal And Installation 1071
Piston And Connecting Rod Inspection 1072
Crankshaft Removal And Installation 1074
Cylinder Block Inspection 1077
Crankshaft Inspection 1079
Connecting Rod Inspection 1079
Engine Component Class 1080
CAMSHAFT 1083
Removal And Installation 1083
Inspecting 1084
GEARCASE 1087
Gearcase Cover Removal And Installation 1087
Gear Backlash 1088
Gear Timing 1089
Idle Gear Removal And Installation 1090
Idle Gear Inspection 1090
TURBOCHARGER 1091
Description 1091
Removal And Installation 1091
Inspection 1094
FLYWHEEL AND HOUSING 1095
Flywheel Removal And Installation 1095
Ring Gear Removal And Installation 1096
Housing Removal And Installation 1096
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 1097
Description 1097
Removal And Installation 1098
Disassembly And Assembly 1102
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1105
AIR CONDITIONING SYSTEM FLOW 1107
Description 1107
Chart 1108
Components 1109
Safety Equipment 1112
REGULAR MAINTENANCE 1113
Filters 1113
Belt Adjustment 1114
Belt Replacement 1114
Condenser 1114
Air Conditioning Lubrication 1114
Air Conditioning Service Chart 1115
Evaporator / Heater Coil 1116
TROUBLESHOOTING 1117
Blower Motor Does Not Operate 1117
Blower Motor Operates Normally, But Air Flow Is Insufficient 1117
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 1117
The Compressor Does Not Operate At All, Or Operates Improperly 1117
Gauge Pressure Related Troubleshooting 1118
Troubleshooting Tree 1120
Temperature / Pressure Chart 1124
Poor A/C Performance 1126
HVAC Repair And Leaks 1127
Electrical System 1128
Engine Coolant Bypassing The Heater Valve 1134
Heater Valve Not Opening Or Closing 1135
SYSTEM CHARGING AND RECLAMATION 1137
Refrigerant Identification 1137
Reclamation And Charging With Recovery / Charging Unit 1138
COMPRESSOR 1141
Removal And Installation 1141
Oil 1142
Oil Check 1143
CONDENSER 1145
Removal And Installation 1145
RECEIVER / DRIER 1147
Receiver / Drier Removal And Installation 1147
Pressure Switch Removal And Installation 1148
Schrader® Valve Removal And Installation 1148
EVAPORATOR / HEATER UNIT 1149
Removal And Installation 1149
THERMOSTAT 1151
Description 1151
Removal And Installation 1152
EXPANSION VALVE 1153
Removal And Installation 1153
EVAPORATOR COIL 1155
Removal And Installation 1155
HEATER COIL 1157
Removal And Installation 1157
BLOWER FAN 1159
Removal And Installation 1159
Disassembly And Assembly 1160
HEATER VALVE 1163
Removal And Installation 1163
EVAPORATOR / HEATER COVER 1165
Removing 1165
Installing 1165
SPECIFICATIONS 1167
(S650) LOADER SPECIFICATIONS 1169
Machine Dimensions 1169
Performance 1170
Engine 1170
Drive System 1171
Controls 1171
Hydraulic System 1172
Electrical System 1173
Capacities 1173
Tires 1174
TECHINCAL SERVICE GUIDE SPECIFICATIONS 1175
Engine 1175
Engine Torques 1175
Cooling System 1175
Loader Torques 1176
Hydraulic / Hydrostatic System 1176
Fuel Consumption 1176
TORQUE SPECIFICATIONS FOR BOLTS 1177
Torque For General SAE Bolts 1177
Torque For General Metric Bolts 1178
HYDRAULIC CONNECTION SPECIFICATIONS 1179
Straight Thread O-ring Fitting 1179
Flare Fitting 1180
Tubelines And Hoses 1180
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 1181
Specifications 1181
CONVERSIONS 1183
Decimal And Millimeter Equivalent Chart 1183
U S To Metric Conversion Chart 1183
SERVICE TOOLS REQUIRED 1185
Remote Start Tools 1185
Hydraulic Tools 1186
Mainframe And Drive Tools 1189
Electrical Tools 1192
Engine Tools 1193
HVAC Tools 1198
ALPHABETICAL INDEX 1199

IMAGES PREVIEW OF THE MANUAL:

Questions? Email us: [email protected]

https://vimeo.com/843869096?share=copy

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V