Bobcat S770 Compact Track Loader Service Manual 7248296 (10-18) – PDF DOWNLOAD

Description

Bobcat S770 Compact Track Loader Service Manual 7248296 (10-18) – PDF DOWNLOAD

FILE DETAILS:

Bobcat S770 Compact Track Loader Service Manual 7248296 (10-18) – PDF DOWNLOAD

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

DESCRIPTION:

Bobcat S770 Compact Track Loader Service Manual 7248296 (10-18) – PDF DOWNLOAD

S/N AT5A11001 & Above
S/N B3BV11001 & 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 S770 Compact Track Loader Service Manual 7248296 (10-18) – 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 Filters 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
DIESEL EXHAUST FLUID (DEF) / ADBLUE® SYSTEM 67
Description 67
Filling The DEF / AdBlue® Tank 67
ENGINE LUBRICATION SYSTEM 69
Checking And Adding Engine Oil 69
Engine Oil Chart 69
Removing And Replacing Oil And Filter 70
HYDRAULIC / HYDROSTATIC SYSTEM 73
Checking And Adding Fluid 73
Hydraulic / Hydrostatic Fluid Chart 73
Removing And Replacing Hydraulic Fluid 74
Removing And Replacing Hydraulic / Hydrostatic Filter 76
Removing And Replacing Hydraulic Charge Filter 77
Replacing Reservoir Breather Cap 78
FINAL DRIVE TRANSMISSION (CHAINCASE) 79
Checking And Adding Fluid 79
Removing And Replacing Fluid 79
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
PIVOT PINS 91
Inspection And Maintenance 91
LOADER STORAGE AND RETURN TO SERVICE 93
Storage 93
Return To Service 93
STOPPING THE ENGINE AND LEAVING THE LOADER 95
Procedure 95
EMERGENCY EXIT 97
Rear Window Identification 97
Rear Window Removal (Latches) 97
Rear Window Removal (Rubber Cord) 97
External Access (Rear Window With Latches) 98
External Access (Rear Window With Rubber Cord) 98
Front Door 98
SEAT BELT 101
Inspection And Maintenance 101
HYDRAULIC SYSTEM 103
HYDRAULIC / HYDROSTATIC SCHEMATICS 109
HYDRAULIC SYSTEM INFORMATION 117
Glossary Of Hydraulic / Hydrostatic Symbols 117
Troubleshooting 121
CYLINDER (LIFT) 123
Testing 123
Removal And Installation 124
Parts Identification 128
Disassembly 129
Assembly 130
CYLINDER (TILT) 135
Testing 135
Removal And Installation 136
Base End Pivot Pin Removal And Installation 138
Parts Identification 139
Disassembly 140
Assembly 142
CYLINDER (BOB-TACH) 145
Testing 145
Removal And Installation 146
Parts Identification 147
Disassembly 148
Assembly 149
MAIN RELIEF VALVE 153
Description 153
Testing 154
Main Relief Valve Adjustment 156
Main Relief Valve Removal And Installation 156
Auxiliary Relief Valve Adjustment 157
Auxiliary Relief Valve Removal And Installation 158
HYDRAULIC CONTROL VALVE (STANDARD) 159
Description 159
Removal And Installation 160
Mount Bracket Removal And Installation 164
Identification Chart 165
Lift Load Check Valve Removal And Installation 166
Load Check Valve Removal And Installation (Tilt And Auxiliary) 167
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 168
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 168
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 169
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 169
Port Relief Valve Removal And Installation 170
Plug Removal And Installation 172
Rubber Boot Removal And Installation 173
End Cap Block Removal And Installation 173
Lift Spool And Detent Removal 174
Lift Spool And Detent Disassembly 176
Lift Spool And Detent Assembly 178
Lift Spool And Detent Installation 180
Tilt Spool Removal And Installation 182
Tilt Spool Disassembly And Assembly 183
Auxiliary Spool Removal And Installation 184
Auxiliary Solenoid Removal And Installation 185
Solenoid Removal And Installation 186
Lock Valve Removal And Installation 187
Lift Arm Bypass Orifice Removal And Installation 189
Main Relief Valve Removal And Installation 189
Auxiliary Relief Valve Removal And Installation 190
Check Valve Removal And Installation 190
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) 193
Description 193
Removal And Installation 193
Actuator Removal And Installation (In Loader) 198
Actuator Removal And Installation (Out Of Loader) 199
Identification Chart 202
Mount Bracket Removal And Installation 203
Lift Load Check Valve Removal And Installation 203
Load Check Valve Removal And Installation (Tilt And Auxiliary) 204
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 205
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 205
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 206
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 206
Port Relief Valve Removal And Installation 207
Plug Removal And Installation 209
End Cap Block Removal And Installation 210
Lift Spool Removal And Installation 210
Lift Spool Disassembly And Assembly 212
Tilt Spool Removal And Installation 213
Auxiliary Spool Removal And Installation 215
Auxiliary Solenoid Removal And Installation 216
Solenoid Removal And Installation 217
Lock Valve Removal And Installation 218
Lift Arm Bypass Orifice Removal And Installation 220
Main Relief Valve Removal And Installation 220
Auxiliary Relief Valve Removal And Installation 221
Check Valve Removal And Installation 221
LIFT ARM BYPASS CONTROL VALVE 223
Description 223
Testing 223
Removal And Installation 224
Bracket Removal And Installation 225
Disassembly And Assembly 225
HYDRAULIC PUMP 227
Description 227
Pump Test At Quick Couplers 227
Direct Pump Test (Standard Section) 228
Direct Pump Test (Charge Section) 230
Removal And Installation 232
Hydraulic Pump Startup 234
Parts Identification 235
Disassembly And Assembly 236
HYDRAULIC PUMP (HIGH FLOW) 237
Description 237
Pump Test At Quick Couplers 237
Direct Pump Test (Standard Section) 238
Direct Pump Test (Charge Section) 239
Direct Pump Test (High Flow Section) 241
High Flow Relief Valve Adjustment 243
High Flow Relief Valve Removal And Installation 244
Solenoid Removal And Installation 245
Removal And Installation 246
Hydraulic Pump Startup 248
Parts Identification 249
Disassembly And Assembly 250
HYDRAULIC / HYDROSTATIC FILTERS 251
Description 251
Housing Removal And Installation 251
HYDRAULIC FLUID RESERVOIR 253
Description 253
Removal And Installation 253
Hydraulic Fluid Screen 254
OIL COOLER 255
Description 255
Removal And Installation 255
BUCKET POSITION VALVE 257
Description 257
Solenoid Removal And Installation 257
Solenoid Testing 259
Removal And Installation 259
Disassembly And Assembly 261
REAR AUXILIARY DIVERTER VALVE 263
Description 263
Solenoid Testing 263
Removal And Installation 264
Disassembly And Assembly 265
BOB-TACH (POWER) BLOCK 271
Description 271
Testing Relief Valve 272
Removal And Installation 274
Disassembly And Assembly 276
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 281
Description 281
Removal And Installation 282
Disassembly And Assembly (FFI/FI) 282
Disassembly And Assembly (FFH/FH) 284
AUTOMATIC RIDE CONTROL 287
Description 287
Removal And Installation 288
Checking The Pressure In The Accumulator 291
Adding Nitrogen To The Accumulator 293
HYDROSTATIC SYSTEM 295
HYDROSTATIC SYSTEM INFORMATION 297
Description 297
Troubleshooting 298
HYDROSTATIC DRIVE MOTOR 299
Description 299
Removal And Installation 300
Parts Identification 302
Disassembly And Assembly 303
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) 307
Description 307
Removal And Installation 307
Parts Identification 310
Disassembly 311
Assembly 317
HYDROSTATIC MOTOR CARRIER 323
Description 323
Removal And Installation 324
Parts Identification 325
Disassembly 326
Assembly 328
HYDROSTATIC MOTOR CARRIER (SJC) 331
Description 331
Removal And Installation 332
Parts Identification 334
Disassembly 335
Assembly 337
CHARGE PRESSURE 339
Description 339
Testing 340
Sender Removal And Installation 342
Adjusting 343
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 397
Hydraulic Controller Neutral Adjustment 400
DRIVE BELT 403
Belt Adjustment 403
Stop Adjustment 403
Belt Replacement 404
Tensioner Pulley Removal And Installation (Earlier Models) 406
Tensioner Pulley Disassembly And Assembly 406
Tensioner Pulley Removal And Installation (Later Models) 407
Tensioner Pulley Disassembly And Assembly 407
TWO-SPEED / BRAKE VALVE 409
Description 409
Valve Block Removal And Installation 410
Valve Block Disassembly And Assembly 412
DRAIN MANIFOLD 415
Description 415
Drain Manifold Removal And Installation 415
DRIVE SYSTEM 417
BRAKE (SINGLE SPEED) 419
Description 419
Disc Removal And Installation 419
BRAKE (TWO-SPEED) 421
Description 421
DRIVE COMPONENTS 423
Description 423
Axle Seal Removal And Installation 424
Axle, Sprocket And Bearings Removal And Installation 426
Chain Removal And Installation 431
CHAINCASE 433
Description 433
Front Cover Removal And Installation 433
Center Cover Removal And Installation 434
Rear Cover Removal And Installation 435
MAINFRAME 437
SEAT BAR 441
Description 441
Removal And Installation 441
Disassembly And Assembly 442
Compression Spring Disassembly And Assembly 443
OPERATOR CAB 445
Gas Spring Removal And Installation 445
Gas Spring Bracket Disassembly And Assembly 446
Removal And Installation 446
OPERATOR SEAT 449
Removal And Installation 449
Seat Belt Removal And Installation (Retractable) 449
Seat Belt And Bracket Removal And Installation (Standard) 450
Seat Belt Bracket Removal And Installation 450
OPERATOR SEAT (SUSPENSION) 451
Removal And Installation 451
Slide Rail Removal And Installation 451
Seat Belt Removal And Installation 452
Lower Cushion Removal 452
Lower Cushion Installation 453
Back Cushion Removal And Installation 453
Shock Removal And Installation 454
3-Point Seat Belt Removal And Installation 454
BOB-TACH (HAND LEVER) 457
Description 457
Removal And Installation 457
Lever And Wedge Disassembly And Assembly 459
Pivot Pin Bushing And Seal Removal And Installation 461
BOB-TACH (POWER) 463
Description 463
Removal And Installation 463
Lever And Wedge Disassembly And Assembly 466
Pivot Pin Bushing And Seal Removal And Installation 468
LIFT ARMS 469
Stabilizer Bar Removal And Installation 469
Link Removal And Installation 470
Removal And Installation 471
REAR GRILLE 475
Removing 475
Installing 475
Shield Removal And Installation 476
ENGINE COVER 477
Removal And Installation 477
REAR DOOR (TAILGATE) 479
Removal And Installation 479
Striker Removal And Installation 480
Striker Disassembly And Assembly 480
Striker (Adjusting) 480
Latch Removal And Installation 481
Tailgate Fan Removal And Installation 482
FUEL TANK 483
Removal And Installation 483
Fuel Level Sender Removal And Installation 484
Fuel Fill Screen Removal And Installation 485
CONTROL PEDALS AND LINKAGES 487
Description 487
Pedal Removal And Installation 487
Linkage Removal And Installation 488
Pedal (Adjusting) 489
Floor Pan Removal And Installation 490
CONTROL PEDALS AND LINKAGES (ACS) 491
Description 491
Pedal Removal And Installation 491
Linkage Removal And Installation 492
Pedal (Adjusting) 492
Floor Pan Removal And Installation 493
CONTROL PANEL 495
Description 495
Removal And Installation 496
Disassembly And Assembly 497
Linkage Removal And Installation 501
Pintle Arm Disassembly And Assembly 505
Linkage Neutral (Adjusting) 506
Linkage Travel (Adjusting) 510
Shock Removal And Installation 514
CONTROL PANEL (SJC) 515
Description 515
Removal And Installation 515
CONTROL HANDLE / LEVER 517
Description 517
Lever Removal And Installation 517
Boot Removal And Installation 518
CONTROL HANDLE / LEVER (ACS) 519
Description 519
Handle Sensor Removal And Installation 519
Handle Removal And Installation 522
Handle Disassembly And Assembly 523
Lever Removal And Installation 523
Boot Removal And Installation 524
CONTROL HANDLE / LEVER (SJC) 525
Description 525
Joystick Testing 525
Joystick Removal And Installation 526
ACCESS PANEL (INSIDE) 527
Removal And Installation (Left) 527
Removal And Installation (Right) 527
ACCESS PANEL (INSIDE) (SJC) 529
Removal And Installation (Left) 529
Removal And Installation (Right) 529
WINDOW (REAR) 531
Rear Window Identification 531
Rear Window Removal (Latches) 531
Rear Window Removal (Rubber Cord) 531
External Access (Rear Window With Latches) 532
External Access (Rear Window With Rubber Cord) 532
WINDOW (TOP) 533
Removal And Installation 533
WINDOW (SIDE) 535
Removal And Installation 535
CAB DOOR 537
Description 537
Removal And Installation 537
Disassembly And Assembly 538
Aligning 539
Adjusting 540
Checking Operation 540
ARMREST 541
Description 541
Removal And Installation 542
Disassembly And Assembly 543
LEFT SIDE LOWER PANEL 545
Removal And Installation 545
Disassembly And Assembly 547
RIGHT SIDE LOWER PANEL 549
Removal And Installation 549
Disassembly And Assembly 550
HEADLINER 553
Removal And Installation 553
FAN DUCT PANELS 555
Removal And Installation 555
ELECTRICAL SYSTEM 557
ELECTRICAL SCHEMATICS 563
ELECTRICAL SYSTEM INFORMATION 717
Glossary Of Electrical Symbols 717
Standard Cab Harness Connectors 720
Deluxe Cab Harness Connectors 721
Mainframe Manual Harness Connectors 722
Mainframe SJC, AHC, ACS Harness Connectors 723
Engine Harness Connectors 724
Description 725
Troubleshooting 726
Fuse And Relay Location / Identification 727
Solenoid Testing 733
BATTERY 735
Removal And Installation 735
Servicing 736
Maintaining Battery Charge Level 736
Battery Service During Machine Storage 736
Battery Testing 737
Battery Charging 737
Using A Booster Battery (Jump Starting) 738
ALTERNATOR 739
Belt Adjustment 739
Belt Replacement 739
Charging System Inspection 740
Alternator Voltage Testing 741
Low Voltage Testing 741
High Voltage Testing 742
Removal And Installation 743
Parts Identification 745
STARTER 747
Testing 747
Removal And Installation 747
Parts Identification 748
INSTRUMENT PANELS 749
Left Panel 749
Display Screen 751
Right Panel (Standard Key Panel) 752
Right Panel (Keyless Start Panel) 753
Right Panel (Deluxe Instrumentation Panel) 754
Left Switch Panel 756
Right Switch Panel 756
Left Side Lower Panel 757
Right Side Lower Panel 757
Left Panel Removal And Installation 758
Right Panel (Standard Key Panel) Removal And Installation 758
Right Panel (Keyless Start Panel) Removal And Installation 759
Right Panel (Deluxe Instrumentation Panel) Removal And Installation 759
Key Switch Disassembly And Assembly 760
Alarm Disassembly And Assembly 760
Left Switch Panel Removal And Installation 761
Right Switch Panel Removal And Installation 761
LIGHTS 763
Front Removal And Installation 763
Rear Removal And Installation 764
Cab Light Removal And Installation 764
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) 765
Description 765
Connector Identification 766
Removal And Installation 772
BOBCAT CONTROLLER (ACS) 773
Description 773
Connector And Wire Identification 774
Removal And Installation 775
BOBCAT CONTROLLER (SJC) (DRIVE) 777
Description 777
Connector Identification 778
Removal And Installation 780
DOSING CONTROL UNIT (DCU) 781
Description 781
Removal And installation 781
ENGINE CONTROL UNIT (ECU) 783
Description 783
Cleaning 784
Removal And Installation 785
DIAGNOSTIC SERVICE CODES 787
Viewing Service Codes 787
Service Codes List 788
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 803
Description 803
Operation 803
Inspecting The BICS™ (Engine STOPPED – Key ON) 804
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 804
Inspecting The Seat Bar Sensor (Engine RUNNING) 804
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 804
Inspecting The Lift Arm Bypass Control 804
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) 804
Troubleshooting 805
SEAT BAR SENSOR 807
Description 807
Troubleshooting 807
Testing 808
Removal 809
Installation 810
Bobcat Interlock Control System (BICS™) Circuit Test 812
TRACTION LOCK 815
Description 815
Troubleshooting 816
Inspecting 817
CONTROL SYSTEM (ACS) 819
Description 819
Troubleshooting 820
Handle Sensor Connector Disassembly And Assembly 821
Switch Handle Removal 822
Switch Handle Installation 824
Actuator Connector Disassembly And Assembly 827
Handle Lock Solenoid Removal And Installation 828
Handle Lock Solenoid Disassembly And Assembly 828
Foot Sensor Removal And Installation 829
Foot Sensor Disassembly And Assembly 830
Foot Sensor Lock Solenoid Removal And Installation 830
ELECTRICAL / HYDRAULIC CONTROLS 831
Identification Chart 831
Description 832
Identification Chart ACD Group 0 833
Identification Chart ACD Group 1 834
Identification Chart ACD Group 2 835
Identification Chart ACD Group 3 836
ELECTRICAL / HYDRAULIC CONTROLS (ACS) 837
Identification Chart 837
Description 838
Identification Chart ACD Group 0 839
Identification Chart ACD Group 1 840
Identification Chart ACD Group 2 841
Identification Chart ACD Group 3 842
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 843
Identification Chart 843
Description 844
Identification Chart ACD Group 0 845
Identification Chart ACD Group 1 846
Identification Chart ACD Group 2 847
Identification Chart ACD Group 3 848
SERVICE PC (LAPTOP COMPUTER) 849
Connecting Remote Start Tool 849
Connecting Remote Start Tool (Service Tool) 849
CALIBRATION 851
Description 851
Actuator Testing 851
Lift And Tilt Calibration (SJC) 854
Hydrostatic Pump Calibration (SJC) 856
Lift And Tilt Calibration (ACS) 861
STEERING DRIFT COMPENSATION (OPERATOR MODE) 863
Description 863
Operation 863
STEERING DRIFT COMPENSATION (SERVICE MODE) 865
Description 865
Operation 865
CONTROL PANEL SETUP 867
Right Panel Setup (Deluxe Instrumentation Panel) 867
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 871
Password Description 871
Changing The Owner Password 871
Changing The User Passwords 872
Password Lockout Feature 872
PASSWORD SETUP (KEYLESS START PANEL) 873
Password Description 873
Changing The Owner Password 873
Password Lockout Feature 873
MAINTENANCE CLOCK 875
Description 875
Setup 876
Reset 879
BACK-UP ALARM SYSTEM 881
Description 881
Inspection 881
Adjusting Switch Position 882
Troubleshooting (Standard And ACS) 883
Troubleshooting (Joystick) 884
Alarm Removal And Installation 885
Switch Removal And Installation 885
FRONT HORN 887
Removal And Installation 887
Troubleshooting 888
Troubleshooting (Joystick) 889
CAMSHAFT AND CRANKSHAFT POSITION SENSOR 891
Removal And Installation 891
ENGINE COMPARTMENT TEMPERATURE SENSOR 893
Removal And Installation 893
TELEMATICS 895
Description 895
Removal And Installation 895
Procedure 896
ENGINE SERVICE 897
ENGINE INFORMATION 901
Description 901
Specifications 902
Sensor Location 904
Torque Values 911
Troubleshooting 913
Engine Removal And Installation 915
Engine Mount Replacement 926
Compression – Testing 928
Injector Signal – Testing 930
Injector Signal – Testing (In-Line) 932
Oil Pressure Testing (At Oil Sensor On Block) 934
Oil Pressure Testing (At Turbocharger Oil Inlet) 936
ENGINE SPEED CONTROL (HAND) 939
Removal And Installation 939
ENGINE SPEED CONTROL (FOOT) 941
Removal And Installation 941
Disassembly And Assembly 942
Foot Throttle Calibration 944
SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM 947
Description 947
Diesel Exhaust Fluid (DEF) / AdBlue® Level 948
DeSOX Process 949
SCR System Codes 951
Diesel Exhaust Fluid (DEF) / AdBlue® Unsatisfactory Quality 952
SCR System Component Tampering 952
EGR Impeded 953
Diesel Exhaust Fluid (DEF) / AdBlue® Dosing Interruption 953
SCR Removal And Installation 954
Dosing Module Removal And Installation 956
Dosing Control Unit (DCU) Removal And Installation 957
Supply Module Removal And Installation 959
Supply Module Filter Removal And Installation 960
Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal And Installation 962
Diesel Exhaust Fluid (DEF) / AdBlue® Sensor Removal And Installation 965
Diesel Exhaust Fluid (DEF) / AdBlue® Coolant Valve Removal And Installation 967
DIESEL OXIDATION CATALYST (DOC) 969
Removal And Installation 969
AIR CLEANER 971
Housing Removal And Installation 971
ENGINE COOLING SYSTEM 973
Radiator Removal And Installation 973
Hydraulic Fan Description 976
Hydraulic Reversing Fan Description 976
Fan Duct Removal And Installation 976
Hydraulic Fan Motor Assembly Removal And Installation 977
Hydraulic Fan Motor Removal And Installation 979
Hydraulic Fan Motor Disassembly And Assembly 980
Blower Housing Removal And Installation 989
Water Pump Removal And Installation 989
Thermostat Housing Removal And Installation 990
Thermostat – Testing 990
LUBRICATION SYSTEM 991
Description 991
Oil Pan Removal And Installation 992
Oil Pump Removal And Installation 993
Oil Pump Relief Valve Description 994
Oil Suction Tube Removal And Installation 994
Oil Cooler Removal And Installation 995
Oil Filter Head Removal And Installation 995
Oil Cooler Bypass Description 996
FUEL SYSTEM 997
Description 997
High Pressure Pump Removal And Installation 998
High Pressure Pump Drive Gear Removal And Installation 999
Fuel Cooler Removal And Installation 1000
Fuel Bypass Valve Removal And Installation 1000
Fuel Temperature Sensor Removal And Installation 1000
Fuel Recirculation Valve Removal And Installation 1001
Fuel Rail Assembly Removal And Installation 1002
Fuel Injector Removal And Installation 1003
Injector Coding 1005
Removing Air From The Fuel System 1007
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
Testing 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
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

IMAGES PREVIEW OF THE MANUAL:

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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