Bobcat S740 Skid-Steer Loader Service Manual 7252363 – PDF DOWNLOAD

Description

Bobcat S740 Skid-Steer Loader Service Manual 7252363 – PDF DOWNLOAD

FILE DETAILS:

Bobcat S740 Skid-Steer Loader Service Manual 7252363 – PDF DOWNLOAD

Language : English
Pages : 1156
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S740 Skid-Steer Loader Service Manual 7252363 – PDF DOWNLOAD

S/N B3BT11001 & Above
S/N B3M311001 & 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 S740 Skid-Steer Loader Service Manual 7252363 – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
LOADER IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE LOADER 23
Procedure 23
LIFT ARM SUPPORT DEVICE 25
Description 25
Installing 26
Removing 27
OPERATOR CAB 29
Description 29
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
ENGINE AIR CLEANER 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
Removing And Replacing Hydraulic / Hydrostatic Filter 74
Removing And Replacing Hydraulic Charge Filter 75
Replacing Reservoir Breather Cap 76
FINAL DRIVE TRANSMISSION (CHAINCASE) 77
Checking And Adding Fluid 77
Removing And Replacing Fluid 77
BOB-TACH (HAND LEVER) 79
Inspection And Maintenance 79
BOB-TACH (POWER) 81
Inspection And Maintenance 81
LUBRICATING THE LOADER 83
Lubrication Locations 83
TIRE MAINTENANCE 87
Wheel Nuts 87
Rotating 87
Mounting 88
PIVOT PINS 89
Inspection And Maintenance 89
LOADER STORAGE AND RETURN TO SERVICE 91
Storage 91
Return To Service 91
STOPPING THE ENGINE AND LEAVING THE LOADER 93
Procedure 93
EMERGENCY EXIT 95
Rear Window Identification 95
Rear Window Removal (Latches) 95
Rear Window Removal (Rubber Cord) 95
External Access (Rear Window With Latches) 96
External Access (Rear Window With Rubber Cord) 96
Front Door 96
SEAT BELT 99
Inspection And Maintenance 99
HYDRAULIC SYSTEM 101
HYDRAULIC / HYDROSTATIC SCHEMATICS 107
HYDRAULIC SYSTEM INFORMATION 119
Glossary Of Hydraulic / Hydrostatic Symbols 119
Troubleshooting 123
CYLINDER (LIFT) 125
Testing 125
Removal And Installation 126
Parts Identification 130
Disassembly 131
Assembly 132
CYLINDER (TILT) 137
Testing 137
Removal And Installation 138
Base End Pivot Pin Removal And Installation 140
Parts Identification 141
Disassembly 142
Assembly 144
CYLINDER (BOB-TACH) 147
Testing 147
Removal And Installation 148
Parts Identification 149
Disassembly 150
Assembly 151
MAIN RELIEF VALVE 155
Description 155
Testing 156
Main Relief Valve Adjustment 158
Main Relief Valve Removal And Installation 158
Auxiliary Relief Valve Adjustment 159
Auxiliary Relief Valve Removal And Installation 160
HYDRAULIC CONTROL VALVE (STANDARD) 161
Description 161
Removal And Installation 162
Mount Bracket Removal And Installation 166
Identification Chart 167
Lift Load Check Valve Removal And Installation 168
Load Check Valve Removal And Installation (Tilt And Auxiliary) 169
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 170
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 170
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 171
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 171
Port Relief Valve Removal And Installation 172
Plug Removal And Installation 174
Rubber Boot Removal And Installation 175
End Cap Block Removal And Installation 175
Lift Spool And Detent Removal 176
Lift Spool And Detent Disassembly 178
Lift Spool And Detent Assembly 180
Lift Spool And Detent Installation 182
Tilt Spool Removal And Installation 184
Tilt Spool Disassembly And Assembly 185
Auxiliary Spool Removal And Installation 186
Auxiliary Solenoid Removal And Installation 187
Solenoid Removal And Installation 188
Lock Valve Removal And Installation 189
Lift Arm Bypass Orifice Removal And Installation 191
Main Relief Valve Removal And Installation 191
Auxiliary Relief Valve Removal And Installation 192
Check Valve Removal And Installation 192
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 195
Description 195
Removal And Installation 195
Actuator Removal And Installation (In Loader) 200
Actuator Removal And Installation (Out Of Loader) 201
Identification Chart 204
Mount Bracket Removal And Installation 205
Lift Load Check Valve Removal And Installation 205
Load Check Valve Removal And Installation (Tilt And Auxiliary) 206
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 207
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 207
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 208
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 208
Port Relief Valve Removal And Installation 209
Plug Removal And Installation 211
End Cap Block Removal And Installation 212
Lift Spool Removal And Installation 212
Lift Spool Disassembly And Assembly 214
Tilt Spool Removal And Installation 215
Auxiliary Spool Removal And Installation 217
Auxiliary Solenoid Removal And Installation 218
Solenoid Removal And Installation 219
Lock Valve Removal And Installation 220
Lift Arm Bypass Orifice Removal And Installation 222
Main Relief Valve Removal And Installation 222
Auxiliary Relief Valve Removal And Installation 223
Check Valve Removal And Installation 223
LIFT ARM BYPASS CONTROL VALVE 225
Description 225
Testing 225
Removal And Installation 226
Bracket Removal And Installation 227
Disassembly And Assembly 227
HYDRAULIC PUMP 229
Description 229
Pump Test At Quick Couplers 229
Direct Pump Test (Standard Section) 230
Direct Pump Test (Charge Section) 232
Removal And Installation 234
Hydraulic Pump Startup 236
Parts Identification 237
Disassembly And Assembly 238
HYDRAULIC PUMP (HIGH FLOW) 239
Description 239
Pump Test At Quick Couplers 239
Direct Pump Test (Standard Section) 240
Direct Pump Test (Charge Section) 241
Direct Pump Test (High Flow Section) 243
High Flow Relief Valve Adjustment 245
High Flow Relief Valve Removal And Installation 246
Solenoid Removal And Installation 247
Removal And Installation 248
Hydraulic Pump Startup 250
Parts Identification 251
Disassembly And Assembly 252
HYDRAULIC / HYDROSTATIC FILTERS 253
Description 253
Housing Removal And Installation 253
HYDRAULIC FLUID RESERVOIR 255
Description 255
Removal And Installation 255
Hydraulic Fluid Screen 256
OIL COOLER 257
Description 257
Removal And Installation 257
BUCKET POSITION VALVE 259
Description 259
Solenoid Removal And Installation 259
Solenoid Testing 261
Removal And Installation 261
Disassembly And Assembly 263
REAR AUXILIARY DIVERTER VALVE 265
Description 265
Solenoid Testing 265
Removal And Installation 266
Disassembly And Assembly 267
BOB-TACH (POWER) BLOCK 273
Description 273
Testing Relief Valve 274
Removal And Installation 276
Disassembly And Assembly 278
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 283
Description 283
Removal And Installation 284
Disassembly And Assembly (FFI/FI) 284
Disassembly And Assembly (FFH/FH) 286
AUTOMATIC RIDE CONTROL 289
Description 289
Removal And Installation 290
Checking The Pressure In The Accumulator 293
Adding Nitrogen To The Accumulator 295
HYDROSTATIC SYSTEM 297
HYDROSTATIC SYSTEM INFORMATION 299
Description 299
Troubleshooting 300
HYDROSTATIC DRIVE MOTOR 301
Description 301
Removal And Installation 302
Parts Identification 304
Disassembly And Assembly 305
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 309
Description 309
Removal And Installation 309
Parts Identification 312
Disassembly 313
Assembly 319
HYDROSTATIC MOTOR CARRIER 325
Description 325
Removal And Installation 326
Parts Identification 327
Disassembly 328
Assembly 329
HYDROSTATIC MOTOR CARRIER (SJC) 331
Description 331
Removal And Installation 332
Parts Identification 334
Disassembly 335
Assembly 337
CHARGE PRESSURE 339
Description 339
Testing 339
Sender Removal And Installation 341
Adjusting 342
HYDROSTATIC PUMP 345
Description 345
Removal And Installation 346
Hydrostatic Pump Startup 347
Replenishing / High Pressure Relief Valve Removal And Installation 347
Parts Identification (Left Half) 348
Parts Identification (Right Half) 349
Disassembly 350
Assembly 357
HYDROSTATIC PUMP (SJC) 365
Description 365
Hydraulic Controller Removal And Installation 366
Removal And Installation 368
Hydrostatic Pump Startup 370
Parts Identification 371
High Pressure Relief And Bypass Valve 372
Charge Relief Valve 373
Disassembly 374
Inspection 383
Assembly 387
Mechanical Neutral Adjustment 395
Hydraulic Controller Neutral Adjustment 398
DRIVE BELT 401
Belt Adjustment 401
Stop Adjustment 401
Belt Replacement 402
Tensioner Pulley Removal And Installation (Earlier Models) 404
Tensioner Pulley Disassembly And Assembly 404
Tensioner Pulley Removal And Installation (Later Models) 405
Tensioner Pulley Disassembly And Assembly 405
TWO-SPEED / BRAKE VALVE 407
Description 407
Valve Block Removal And Installation 408
Valve Block Disassembly And Assembly 410
DRAIN MANIFOLD 413
Description 413
Drain Manifold Removal And Installation 413
DRIVE SYSTEM 415
BRAKE (SINGLE SPEED) 417
Description 417
Disc Removal And Installation 417
BRAKE (TWO-SPEED) 419
Description 419
DRIVE COMPONENTS 421
Description 421
Axle Seal Removal And Installation 422
Axle, Sprocket And Bearings Removal And Installation 424
Chain Removal And Installation 429
CHAINCASE 431
Description 431
Front Cover Removal And Installation 431
Center Cover Removal And Installation 432
Rear Cover Removal And Installation 433
MAINFRAME 435
SEAT BAR 439
Description 439
Removal And Installation 439
Disassembly And Assembly 440
Compression Spring Disassembly And Assembly 441
OPERATOR CAB 443
Gas Spring Removal And Installation 443
Gas Spring Bracket Disassembly And Assembly 444
Removal And Installation 444
OPERATOR SEAT 447
Removal And Installation 447
Seat Belt Removal And Installation (Retractable) 447
Seat Belt And Bracket Removal And Installation (Standard) 448
Seat Belt Bracket Removal And Installation 448
OPERATOR SEAT (SUSPENSION) 449
Removal And Installation 449
Slide Rail Removal And Installation 449
Seat Belt Removal And Installation 450
Lower Cushion Removal 450
Lower Cushion Installation 451
Back Cushion Removal And Installation 451
Shock Removal And Installation 452
3-Point Seat Belt Removal And Installation 452
BOB-TACH (HAND LEVER) 455
Description 455
Removal And Installation 455
Lever And Wedge Disassembly And Assembly 457
Pivot Pin Bushing And Seal Removal And Installation 459
BOB-TACH (POWER) 461
Description 461
Removal And Installation 461
Lever And Wedge Disassembly And Assembly 464
Pivot Pin Bushing And Seal Removal And Installation 466
LIFT ARMS 467
Stabilizer Bar Removal And Installation 467
Link Removal And Installation 468
Removal And Installation 469
REAR GRILLE 473
Removing 473
Installing 473
Shield Removal And Installation 474
ENGINE COVER 475
Removal And Installation 475
REAR DOOR (TAILGATE) 477
Removal And Installation 477
Striker Removal And Installation 478
Striker Disassembly And Assembly 478
Striker (Adjusting) 478
Latch Removal And Installation 479
FUEL TANK 481
Removal And Installation 481
Fuel Level Sender Removal And Installation 482
Fuel Fill Screen Removal And Installation 483
CONTROL PEDALS AND LINKAGES 485
Description 485
Pedal Removal And Installation 485
Linkage Removal And Installation 486
Pedal (Adjusting) 488
Floor Pan Removal And Installation 488
CONTROL PEDALS AND LINKAGES (ACS) 489
Description 489
Pedal Removal And Installation 489
Linkage Removal And Installation 490
Pedal (Adjusting) 490
Floor Pan Removal And Installation 491
CONTROL PANEL 493
Description 493
Removal And Installation 494
Disassembly And Assembly 495
Linkage Removal And Installation 499
Pintle Arm Disassembly And Assembly 503
Linkage Neutral (Adjusting) 504
Linkage Travel (Adjusting) 508
Shock Removal And Installation 512
CONTROL PANEL (SJC) 513
Description 513
Removal And Installation 513
CONTROL HANDLE / LEVER 515
Description 515
Lever Removal And Installation 515
Boot Removal And Installation 516
CONTROL HANDLE / LEVER (ACS) 517
Description 517
Handle Sensor Removal And Installation 517
Handle Removal And Installation 520
Handle Disassembly And Assembly 521
Lever Removal And Installation 521
Boot Removal And Installation 522
CONTROL HANDLE / LEVER (SJC) 523
Description 523
Joystick Testing 523
Joystick Removal And Installation 524
ACCESS PANEL (INSIDE) 525
Removal And Installation (Left) 525
Removal And Installation (Right) 525
ACCESS PANEL (INSIDE) (SJC) 527
Removal And Installation (Left) 527
Removal And Installation (Right) 527
WINDOW (REAR) 529
Rear Window Identification 529
Removal And Installation (Latches) 529
Disassembly And Assembly (Latches) 530
Removal (Rubber Cord) 531
Installation (Rubber Cord) 532
WINDOW (TOP) 535
Removal And Installation 535
WINDOW (SIDE) 537
Removal And Installation 537
CAB DOOR 539
Description 539
Removal And Installation 539
Disassembly And Assembly 540
Aligning 541
Adjusting 542
Checking Operation 542
ARMREST 543
Description 543
Removal And Installation 544
Disassembly And Assembly 545
LEFT SIDE LOWER PANEL 547
Removal And Installation 547
Disassembly And Assembly 549
RIGHT SIDE LOWER PANEL 551
Removal And Installation 551
Disassembly And Assembly 552
HEADLINER 555
Removal And Installation 555
FAN DUCT PANELS 557
Removal And Installation 557
ELECTRICAL SYSTEM 559
ELECTRICAL SCHEMATICS 565
ELECTRICAL SYSTEM INFORMATION 743
Glossary Of Electrical Symbols 743
Standard Cab Harness Connectors 746
Deluxe Cab Harness Connectors 747
Mainframe Harness Connectors 748
Engine Harness Connectors 749
Description 750
Troubleshooting 751
Fuse And Relay Location / Identification 752
BATTERY 759
Removal And Installation 759
Servicing 760
Maintaining Battery Charge Level 760
Battery Service During Machine Storage 760
Battery Testing 761
Battery Charging 761
Using A Booster Battery (Jump Starting) 762
ALTERNATOR 763
Belt Adjustment 763
Belt Replacement 763
Charging System Inspection 764
Alternator Voltage Testing 765
Low Voltage Testing 765
High Voltage Testing 766
Removal And Installation 767
Parts Identification 769
STARTER 771
Testing 771
Removal And Installation 771
Parts Identification 772
INSTRUMENT PANELS 773
Left Panel 773
Display Screen 775
Right Panel (Standard Key Panel) 776
Right Panel (Keyless Start Panel) 777
Right Panel (Deluxe Instrumentation Panel) 778
Left Switch Panel 780
Right Switch Panel 780
Left Side Lower Panel 781
Right Side Lower Panel 781
Left Panel Removal And Installation 782
Right Panel (Standard Key Panel) Removal And Installation 782
Right Panel (Keyless Start Panel) Removal And Installation 783
Right Panel (Deluxe Instrumentation Panel) Removal And Installation 783
Key Switch Disassembly And Assembly 784
Alarm Disassembly And Assembly 784
Left Switch Panel Removal And Installation 785
Right Switch Panel Removal And Installation 785
LIGHTS 787
Front Removal And Installation 787
Rear Removal And Installation 788
Cab Light Removal And Installation 788
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) 789
Description 789
Connector Identification 790
Removal And Installation 796
BOBCAT CONTROLLER (ACS) 797
Description 797
Connector And Wire Identification 798
Removal And Installation 799
BOBCAT CONTROLLER (SJC) (DRIVE) 801
Description 801
Connector Identification 802
Removal And Installation 804
ENGINE CONTROL UNIT (ECU) 805
Description 805
Cleaning 806
Removal And Installation 807
DIAGNOSTIC SERVICE CODES 809
Viewing Service Codes 809
Service Codes List 810
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 825
Description 825
Operation 825
Inspecting The BICS™ (Engine STOPPED – Key ON) 826
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 826
Inspecting The Seat Bar Sensor (Engine RUNNING) 826
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 826
Inspecting The Lift Arm Bypass Control 826
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) 826
Troubleshooting 827
SEAT BAR SENSOR 829
Description 829
Troubleshooting 829
Testing 830
Removal 831
Installation 832
Bobcat Interlock Control System (BICS™) Circuit Test 834
TRACTION LOCK 837
Description 837
Troubleshooting 838
Inspecting 839
CONTROL SYSTEM (ACS) 841
Description 841
Troubleshooting 842
Handle Sensor Connector Disassembly And Assembly 843
Switch Handle Removal 844
Switch Handle Installation 846
Actuator Connector Disassembly And Assembly 849
Handle Lock Solenoid Removal And Installation 850
Handle Lock Solenoid Disassembly And Assembly 850
Foot Sensor Removal And Installation 851
Foot Sensor Disassembly And Assembly 852
Foot Sensor Lock Solenoid Removal And Installation 852
ELECTRICAL / HYDRAULIC CONTROLS 853
Identification Chart 853
Description 854
Identification Chart ACD Group 0 855
Identification Chart ACD Group 1 856
Identification Chart ACD Group 2 857
Identification Chart ACD Group 3 858
ELECTRICAL / HYDRAULIC CONTROLS (ACS) 859
Identification Chart 859
Description 860
Identification Chart ACD Group 0 861
Identification Chart ACD Group 1 862
Identification Chart ACD Group 2 863
Identification Chart ACD Group 3 864
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 865
Identification Chart 865
Description 866
Identification Chart ACD Group 0 867
Identification Chart ACD Group 1 868
Identification Chart ACD Group 2 869
Identification Chart ACD Group 3 870
SERVICE PC (LAPTOP COMPUTER) 871
Connecting Remote Start Tool 871
Connecting Remote Start Tool (Service Tool) 871
CALIBRATION 873
Description 873
Actuator Testing 873
Lift And Tilt Calibration (SJC) 876
Hydrostatic Pump Calibration (SJC) 878
Lift And Tilt Calibration (ACS) 883
STEERING DRIFT COMPENSATION (OPERATOR MODE) 885
Description 885
Operation 885
STEERING DRIFT COMPENSATION (SERVICE MODE) 887
Description 887
Operation 887
CONTROL PANEL SETUP 889
Right Panel Setup (Deluxe Instrumentation Panel) 889
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 893
Password Description 893
Changing The Owner Password 893
Changing The User Passwords 894
Password Lockout Feature 894
PASSWORD SETUP (KEYLESS START PANEL) 895
Password Description 895
Changing The Owner Password 895
Password Lockout Feature 895
MAINTENANCE CLOCK 897
Description 897
Setup 898
Reset 901
BACK-UP ALARM SYSTEM 903
Description 903
Inspection 903
Adjusting Switch Position 904
Troubleshooting (Standard And ACS) 905
Troubleshooting (Joystick) 906
Alarm Removal And Installation 907
Switch Removal And Installation 907
FRONT HORN 909
Removal And Installation 909
Troubleshooting 910
Troubleshooting (Joystick) 911
ENGINE SPEED CONTROL (HAND) 913
Removal And Installation 913
ENGINE SPEED CONTROL (FOOT) 915
Removal And Installation 915
Disassembly And Assembly 916
Foot Throttle Calibration 918
CAMSHAFT AND CRANKSHAFT POSITION SENSOR 921
Removal And Installation 921
BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS 923
Description 923
Removal And Installation 923
Procedure 924
ENGINE SERVICE 925
ENGINE INFORMATION 929
Description 929
Specifications 930
Sensor Location 932
Torque Values 938
Troubleshooting 940
Engine Removal And Installation 942
Engine Mount Replacement 953
Compression – Testing 955
Injector Signal – Testing 957
Injector Signal – Testing (In-Line) 959
Oil Pressure Testing (At Oil Sensor On Block) 961
Oil Pressure Testing (At Turbocharger Oil Inlet) 963
DIESEL OXIDATION CATALYST (DOC) 965
Removal And Installation 965
AIR CLEANER 967
Housing Removal And Installation 967
ENGINE COOLING SYSTEM 969
Radiator / Oil Cooler Removal And Installation 969
Hydraulic Fan Description 972
Reversible Hydraulic Fan Description 972
Fan Duct Removal And Installation 972
Hydraulic Fan Motor Assembly Removal And Installation 973
Hydraulic Fan Motor Removal And Installation 974
Hydraulic Fan Motor Disassembly And Assembly 976
Blower Housing Removal And Installation 984
Water Pump Removal And Installation 985
Thermostat Housing Removal And Installation 986
Thermostat-Testing 987
LUBRICATION SYSTEM 989
Description 989
Oil Pan Removal And Installation 990
Oil Pump Removal And Installation 991
Oil Pump Relief Valve Description 992
Oil Suction Tube Removal And Installation 992
Oil Cooler Removal And Installation 993
Oil Filter Head Removal And Installation 993
Oil Cooler Bypass Description 994
FUEL SYSTEM 995
Description 995
High Pressure Pump Removal And Installation 996
High Pressure Pump Drive Gear Removal And Installation 997
Fuel Cooler Removal And Installation 998
Fuel Bypass Valve Removal And Installation 998
Fuel Temperature Sensor Removal And Installation 998
Fuel Recirculation Valve Removal And Installation 999
Fuel Rail Assembly Removal And Installation 1000
Fuel Injector Removal And Installation 1001
Injector Coding 1004
Removing Air From The Fuel System 1006
CYLINDER HEAD 1009
Intake Air Heater Removal And Installation 1009
Intake Air Heater Tube Removal And Installation 1010
Valve Clearance Adjustment 1011
Cylinder Head Removal And Installation 1013
Cylinder Head Disassembly And Assembly 1016
Cylinder Head Inspection 1017
Cylinder Head Top Clearance 1018
Valve Step Height 1019
Valve Stem Height 1019
Valve Guide 1020
Valve 1020
Valve Spring 1021
Rocker Arm Shaft Disassembly And Assembly 1022
Rocker Arm Shaft Inspection 1023
Push Rod Inspection 1023
CRANKSHAFT AND PISTONS 1025
Piston And Connecting Rod Removal And Installation 1025
Piston And Connecting Rod Inspection 1026
Timing Wheel Removal And Installation 1028
Crankshaft Removal And Installation 1030
Cylinder Block Inspection 1032
Crankshaft Inspection 1034
Connecting Rod Inspection 1034
Engine Component Class 1035
CAMSHAFT 1037
Removal And Installation 1037
Inspecting 1038
GEARCASE 1041
Gear Backlash 1041
Gear End Play 1041
Gear Timing 1042
Idle Gear Removal And Installation 1043
Idle Gear Inspection 1043
TURBOCHARGER 1045
Description 1045
Removal And Installation 1045
Inspection 1047
FLYWHEEL AND HOUSING 1049
Flywheel Removal And Installation 1049
Ring Gear Removal And Installation 1049
Housing Removal And Installation 1050
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 1051
Description 1051
Removal And Installation 1052
Disassembly And Assembly 1053
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1055
AIR CONDITIONING SYSTEM FLOW 1057
Description 1057
Chart 1058
Components 1059
Safety Equipment 1062
REGULAR MAINTENANCE 1063
Filters 1063
Belt Adjustment 1064
Belt Replacement 1064
Condenser 1065
Air Conditioning Lubrication 1065
Air Conditioning Service Chart 1066
Air Conditioning Evaporator / Heater Coil 1067
TROUBLESHOOTING 1069
Blower Motor Does Not Operate 1069
Blower Motor Operates Normally, But Air Flow Is Insufficient 1069
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 1069
The Compressor Does Not Operate At All, Or Operates Improperly 1069
Gauge Pressure Related Troubleshooting 1070
Troubleshooting Tree 1072
Temperature / Pressure Chart 1075
Poor A/C Performance 1077
HVAC Repair And Leaks 1078
Electrical System 1079
Engine Coolant Bypassing The Heater Valve 1085
Heater Valve Not Opening Or Closing 1086
SYSTEM CHARGING AND RECLAMATION 1087
Refrigerant Identification 1087
Reclamation And Charging With Recovery / Charging Unit 1088
COMPRESSOR 1091
Removal And Installation 1091
Oil 1093
Oil Check 1094
CONDENSER 1095
Removal And Installation 1095
RECEIVER / DRIER 1097
Receiver / Drier Removal And Installation 1097
Pressure Switch Removal And Installation 1099
Schrader® Valve Removal And Installation 1100
EVAPORATOR / HEATER UNIT 1101
Removal And Installation 1101
THERMOSTAT 1103
Description 1103
Removal And Installation 1104
EXPANSION VALVE 1105
Removal And Installation 1105
EVAPORATOR COIL 1107
Removal And Installation 1107
HEATER COIL 1109
Removal And Installation 1109
BLOWER FAN 1111
Removal And Installation 1111
Disassembly And Assembly 1111
HEATER VALVE 1115
Removal And Installation 1115
EVAPORATOR / HEATER COVER 1117
Removing 1117
Installing 1117
SPECIFICATIONS 1119
LOADER SPECIFICATIONS 1121
Machine Dimensions 1121
Performance 1122
Engine 1122
Drive System 1123
Controls 1123
Hydraulic System 1124
Electrical System 1125
Capacities 1125
Tires 1126
TECHINCAL SERVICE GUIDE SPECIFICATIONS 1127
Engine 1127
Engine Torques 1127
Cooling System 1127
Loader Torques 1128
Hydraulic / Hydrostatic System 1128
Fuel Consumption 1128
TORQUE SPECIFICATIONS FOR BOLTS 1129
Torque For General SAE Bolts 1129
Torque For General Metric Bolts 1130
HYDRAULIC CONNECTION SPECIFICATIONS 1131
Straight Thread O-ring Fitting 1131
Flare Fitting 1132
Tubelines And Hoses 1132
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 1133
Specifications 1133
CONVERSIONS 1135
Decimal And Millimeter Equivalent Chart 1135
U S To Metric Conversion Chart 1135
SERVICE TOOLS REQUIRED 1137
Remote Start Tools 1137
Hydraulic Tools 1138
Mainframe And Drive Tools 1141
Electrical Tools 1144
Engine Tools 1145
HVAC Tools 1150
ALPHABETICAL INDEX 1151

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• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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