Bobcat S850 Skid-Steer Loader Service Manual 7253829 – PDF DOWNLOAD

Description

Bobcat S850 Skid-Steer Loader Service Manual 7253829 – PDF DOWNLOAD

FILE DETAILS:

Bobcat S850 Skid-Steer Loader Service Manual 7253829 – PDF DOWNLOAD

Language : English
Pages : 1126
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat S850 Skid-Steer Loader Service Manual 7253829 – PDF DOWNLOAD

S/N AJ9C11001 & Above
S/N B3BY11001 & Above
S/N B47711001 & 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 S850 Skid-Steer Loader Service Manual 7253829 – 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 29
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 Hydraulic 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) 96
External Access (Rear Window With Latches) 96
External Access (Rear Window With Rubber Cord) 97
Front Door 97
SEAT BELT 99
Inspection And Maintenance 99
AUTOMATIC RIDE CONTROL 101
Description 101
Procedure 101
Checking Accumulator Charge 102
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 131
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 150
MAIN RELIEF VALVES 153
Description 153
Testing 153
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 (SJC) 159
Description 159
Removal And Installation 159
Actuator Removal And Installation (In Loader) 164
Actuator Removal And Installation (Out Of Loader) 165
Identification Chart 168
Mount Bracket Removal And Installation 169
Lift Load Check Valve Removal And Installation 169
Load Check Valve Removal And Installation (Tilt And Auxiliary) 170
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 171
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 171
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 172
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 172
Port Relief Valve Removal And Installation 173
Plug Removal And Installation 175
End Cap Block Removal And Installation 176
Lift Spool Removal And Installation 176
Lift Spool Disassembly And Assembly 178
Tilt Spool Removal And Installation 179
Auxiliary Spool Removal And Installation 181
Auxiliary Solenoid Removal And Installation 182
Solenoid Removal And Installation 183
Lock Valve Removal And Installation 184
Lift Arm Bypass Orifice Removal And Installation 186
Main Relief Valve Removal And Installation 186
Auxiliary Relief Valve Removal And Installation 187
Check Valve Removal And Installation 187
HYDRAULIC CONTROL VALVE (SCPA) 189
Description 189
Removal And Installation 190
Mount Bracket Removal And Installation 194
Identification Chart 195
Lift Load Check Valve Removal And Installation 196
Load Check Valve Removal And Installation (Tilt And Auxiliary) 197
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 198
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) 198
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) 199
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) 199
Port Relief Valve Removal And Installation 200
Plug Removal And Installation 202
Rubber Boot Removal And Installation 203
End Cap Block Removal And Installation 203
Lift Spool And Detent Removal And Installation 204
Tilt Spool Removal And Installation 212
Auxiliary Spool Removal And Installation 214
Auxiliary Solenoid Removal And Installation 215
Solenoid Removal And Installation 215
Lock Valve Removal And Installation 217
Lift Arm Bypass Orifice Removal And Installation 219
Main Relief Valve Removal And Installation 219
Auxiliary Relief Valve Removal And Installation 220
Check Valve Removal And Installation 220
LIFT ARM BYPASS CONTROL VALVE 223
Description 223
Testing 223
Removal And Installation 224
Bracket Removal And Installation 225
Disassembly And Assembly 226
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
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 281
Disassembly And Assembly 281
AUTOMATIC RIDE CONTROL 285
Description 285
Removal And Installation 286
Checking The Pressure In The Accumulator 289
Adding Nitrogen To The Accumulator 291
HYDROSTATIC SYSTEM 293
HYDROSTATIC SYSTEM INFORMATION 295
Description 295
Troubleshooting 296
HYDROSTATIC MOTOR (TWO-SPEED) 297
Description 297
Removal And Installation 297
Parts Identification 300
Disassembly 301
Assembly 307
HYDROSTATIC MOTOR CARRIER (SJC AND SCPA) 313
Description 313
Removal And Installation 314
Parts Identification 316
Disassembly 317
Assembly 319
CHARGE PRESSURE 321
Description 321
Testing 321
Sender Removal And Installation 323
Adjusting 324
HYDROSTATIC PUMP (SJC AND SCPA) 325
Description 325
Hydraulic Controller Removal And Installation 326
Removal And Installation 328
Hydrostatic Pump Startup 329
Parts Identification 330
High Pressure Relief And Bypass Valve 331
Charge Relief Valve 332
Disassembly 333
Inspection 342
Assembly 345
Mechanical Neutral Adjustment 355
Hydraulic Controller Neutral Adjustment 358
DRIVE BELT 361
Belt Adjustment 361
Stop Adjustment 361
Belt Replacement 362
Tensioner Pulley Removal And Installation 364
Tensioner Pulley Disassembly And Assembly 365
TWO-SPEED / BRAKE VALVE 367
Description 367
Valve Block Removal And Installation 368
Valve Block Disassembly And Assembly 370
DRAIN MANIFOLD 373
Description 373
Drain Manifold Removal And Installation 373
DRIVE SYSTEM 375
BRAKE (TWO-SPEED) 377
Description 377
DRIVE COMPONENTS 379
Description 379
Axle Seal Removal And Installation 380
Axle, Sprocket And Bearings Removal And Installation 382
Chain Removal And Installation 386
CHAINCASE 389
Description 389
Front Cover Removal And Installation 389
Center Cover Removal And Installation 390
Rear Cover Removal And Installation 391
MAINFRAME 393
SEAT BAR 397
Description 397
Removal And Installation 397
Disassembly And Assembly 398
Compression Spring Disassembly And Assembly 399
OPERATOR CAB 401
Gas Spring Removal And Installation 401
Gas Spring Bracket Disassembly And Assembly 402
Removal And Installation 403
OPERATOR SEAT (SUSPENSION) 405
Removal And Installation 405
Slide Rail Removal And Installation 405
Seat Belt Removal And Installation 406
Lower Cushion Removal 406
Lower Cushion Installation 407
Back Cushion Removal And Installation 407
Shock Removal And Installation 408
3-Point Seat Belt Removal And Installation 408
BOB-TACH (HAND LEVER) 411
Description 411
Removal And Installation 412
Lever And Wedge Disassembly And Assembly 414
Pivot Pin Bushing And Seal Removal And Installation 416
BOB-TACH (POWER) 417
Description 417
Removal And Installation 417
Lever And Wedge Disassembly And Assembly 420
Pivot Pin Bushing And Seal Removal And Installation 422
LIFT ARMS 423
Stabilizer Bar Removal And Installation 423
Link Removal And Installation 424
Removal And Installation 425
REAR GRILLE 429
Removing 429
Installing 429
Shield Removal And Installation 430
REAR DOOR (TAILGATE) 431
Removal And Installation 431
Striker Removal And Installation 432
Striker Disassembly And Assembly 432
Striker (Adjusting) 432
Latch Removal And Installation 433
Tailgate Fan Removal And Installation 434
FUEL TANK 435
Removal And Installation 435
Fuel Level Sender Removal And Installation 436
Fuel Fill Screen Removal And Installation 437
FUEL TANK (AUXILIARY) 439
Removal And Installation 439
CONTROL PEDALS AND LINKAGES (SCPA) 441
Description 441
Pedal Removal And Installation 441
Linkage Removal And Installation 442
Pedal (Adjusting) 443
Floor Pan Removal And Installation 444
CONTROL PANEL (SJC) 445
Description 445
Removal And Installation 445
CONTROL PANEL (SCPA) 447
Description 447
Removal And Installation 447
CONTROL HANDLE / LEVER (SJC) 449
Description 449
Joystick Testing 449
Joystick Removal And Installation 450
CONTROL HANDLE / LEVER (SCPA) 451
Description 451
Steering Handle Testing 451
Steering Handle Removal And Installation 452
ACCESS PANEL (INSIDE) (SJC) 453
Removal And Installation (Left) 453
Removal And Installation (Right) 453
ACCESS PANEL (INSIDE) (SCPA) 455
Removal And Installation (Left) 455
Removal And Installation (Right) 455
WINDOW (REAR) 457
Rear Window Identification 457
Removal (Rubber Cord) 457
Installation (Rubber Cord) 458
Removal And Installation (Latches) 460
Disassembly And Assembly (Latches) 460
WINDOW (TOP) 461
Removal And Installation 461
WINDOW (SIDE) 463
Removal And Installation 463
CAB DOOR 465
Description 465
Removal And Installation 465
Disassembly And Assembly 466
Aligning 467
Adjusting 468
Checking Operation 468
ARMREST 469
Description 469
Removal And Installation 470
Disassembly And Assembly 471
LEFT SIDE LOWER PANEL 473
Removal And Installation 473
Disassembly And Assembly 475
RIGHT SIDE LOWER PANEL 477
Removal And Installation 477
Disassembly And Assembly 478
HEADLINER 481
Removal And Installation 481
FAN DUCT PANELS 483
Removal And Installation 483
ELECTRICAL SYSTEM AND ANALYSIS 485
ELECTRICAL SCHEMATICS 491
ELECTRICAL SYSTEM INFORMATION 677
Glossary Of Electrical Symbols 677
Deluxe Cab Harness Connectors 680
SCPA Mainframe Harness Connectors 681
SJC Mainframe Harness Connectors 682
Engine Harness Connectors 683
Description 684
Troubleshooting 685
Fuse And Relay Location / Identification 686
Solenoid Testing 691
BATTERY 693
Battery Maintenance 693
Maintaining Battery Charge Level 693
Battery Service During Machine Storage 693
Battery Testing 694
Battery Charging 694
Removal And Installation 695
Using A Booster Battery (Jump Starting) 696
ALTERNATOR 697
Belt Adjustment 697
Belt Replacement 697
Charging System Inspection 698
Alternator Voltage Testing 699
Low Voltage Testing 699
High Voltage Testing 700
Removal And Installation 701
STARTER 705
Testing 705
Removal And Installation 705
Parts Identification 706
INSTRUMENT PANELS 707
Left Panel 707
Display Screen 709
Right Panel (Standard Key Panel) 710
Right Panel (Keyless Start Panel) 711
Right Panel (Deluxe Instrumentation Panel) 712
Left Switch Panel 714
Right Switch Panel 714
Left Side Lower Panel 715
Right Side Lower Panel 715
Radio 716
Rear View Camera System 718
Left Panel Removal And Installation 720
Right Panel Removal And Installation 720
Key Switch Disassembly And Assembly 721
Alarm Disassembly And Assembly 721
Left Switch Panel Removal And Installation 722
Right Switch Panel Removal And Installation 722
LIGHTS 723
Front Removal And Installation 723
Rear Removal And Installation 724
Cab Light Removal And Installation 724
BOBCAT CONTOLERS (GATEWAY AND AUXILLIARY) 725
Description 725
Connector Identification 726
Removal And Installation 732
BOBCAT CONTROLLER (ACS) 733
Description 733
Connector And Wire Identification 734
Removal And Installation 736
BOBCAT CONTROLLER (SJC) (DRIVE) 737
Description 737
Connector Identification (Earlier Models) 738
Removal And Installation (Earlier Models) 740
Connector Identification (Later Models) 742
Removal And Installation (Later Models) 745
BOBCAT CONTROLLER (SCPA) (DRIVE) 747
Description 747
Connector Identification (Earlier Models) 748
Removal And Installation (Earlier Models) 750
Connector Identification (Later Models) 752
Removal And Installation (Later Models) 755
DOSING CONTROL UNIT (DCU) 757
Description 757
Removal And installation 757
ENGINE CONTROL UNIT (ECU) 759
Description 759
Cleaning 760
Removal And Installation 761
DIAGNOSTIC SERVICE CODES 763
Viewing Service Codes 763
Service Codes List 764
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 779
Description 779
Inspecting The BICS™ (Engine STOPPED – Key ON) 780
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 780
Inspecting The Seat Bar Sensor (Engine RUNNING) 780
Inspecting The Traction Lock And Parking Brake (Engine RUNNING) 780
Inspecting The Lift Arm Bypass Control 780
Inspecting Deactivation Of Lift And Tilt Functions (SJC) 780
Troubleshooting 781
SEAT BAR SENSOR 783
Description 783
Troubleshooting 783
Testing 784
Removal And Installation 785
Bobcat Interlock Control System (BICS™) Circuit Test 788
TRACTION LOCK 791
Description 791
Troubleshooting 792
Inspecting 793
ELECTRICAL / HYDRAULIC CONTROLS (SJC) 795
Identification Chart 795
Description 796
Identification Chart ACD Group 0 797
Identification Chart ACD Group 1 798
Identification Chart ACD Group 2 799
Identification Chart ACD Group 3 800
ELECTRICAL / HYDRAULIC CONTROLS (SCPA) 801
Identification Chart 801
Description 802
Identification Chart ACD Group 0 803
Identification Chart ACD Group 1 804
Identification Chart ACD Group 2 805
Identification Chart ACD Group 3 806
SERVICE PC (LAPTOP COMPUTER) 807
Connecting Remote Start Tool 807
Connecting Remote Start Tool (Service Tool) 807
CALIBRATION 809
Description 809
Actuator Testing 809
Lift And Tilt Calibration (SJC) 812
Hydrostatic Pump Calibration (SJC) 814
Hydrostatic Pump Calibration (SCPA) 819
STEERING DRIFT COMPENSATION (OPERATOR MODE) 825
Description 825
Operation 825
STEERING DRIFT COMPENSATION (SERVICE MODE) 827
Description 827
Operation 827
CONTROL PANEL SETUP 829
Right Panel Setup (Deluxe Instrumentation Panel) 829
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) 833
Password Description 833
Changing The Owner Password 833
Changing The User Passwords 834
Password Lockout Feature 834
PASSWORD SETUP (KEYLESS START PANEL) 835
Password Description 835
Changing The Owner Password 835
Password Lockout Feature 835
MAINTENANCE CLOCK 837
Description 837
Setup 838
Reset 841
BACK-UP ALARM SYSTEM 843
Description 843
Inspecting 843
Troubleshooting (Joystick) 844
Alarm Removal And Installation 845
FRONT HORN 847
Removal And Installation 847
Troubleshooting 848
Troubleshooting (Joystick) 849
ENGINE COMPARTMENT TEMPERATURE SENSOR 851
Removal And Installation 851
BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS 853
Description 853
Controller Removal And Installation 853
Procedure 855
ENGINE SERVICE 857
ENGINE INFORMATION 861
Description 861
Specifications 862
Sensor Location 864
Torque Values 871
Troubleshooting 873
Engine Removal And Installation 875
Engine Mount Replacement 886
Compression – Testing 888
Injector Signal – Testing 890
Injector Signal – Testing (In-Line) 892
Oil Pressure Testing (At Oil Sensor On Block) 894
Oil Pressure Testing (At Turbocharger Oil Inlet) 896
ENGINE SPEED CONTROL (HAND) 899
Removal And Installation 899
ENGINE SPEED CONTROL (FOOT) (EARLIER MODELS) 901
Removal And Installation 901
Disassembly And Assembly 902
Foot Throttle Calibration 904
ENGINE SPEED CONTROL (FOOT) (LATER MODELS) 907
Removal And Installation 907
Disassembly And Assembly 908
SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM 909
Description 909
Diesel Exhaust Fluid (DEF) / AdBlue® Level 910
DeSOX Process 911
SCR System Codes 913
Diesel Exhaust Fluid (DEF) / AdBlue® Unsatisfactory Quality 914
SCR System Component Tampering 914
EGR Impeded 915
Diesel Exhaust Fluid (DEF) / AdBlue® Dosing Interruption 915
SCR Removal And Installation 916
Dosing Module Removal And Installation 918
Dosing Control Unit (DCU) Removal And Installation 919
Supply Module Removal And Installation 921
Supply Module Filter Removal And Installation 922
Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal And Installation (Earlier Models) 924
Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal And Installation (Later Models) 927
Diesel Exhaust Fluid (DEF) / AdBlue® Sensor Removal And Installation (Later Models) 929
Diesel Exhaust Fluid (DEF) / AdBlue® Coolant Valve Removal And Installation 931
DIESEL OXIDATION CATALYST (DOC) 933
Removal And Installation 933
AIR CLEANER 935
Housing Removal And Installation 935
ENGINE COOLING SYSTEM 937
Radiator / Oil Cooler Removal And Installation 937
Hydraulic Fan Description 940
Hydraulic Reversing Fan Description 940
Lower Fan Duct Removal And Installation 940
Hydraulic Fan Motor Assembly Removal And Installation 941
Hydraulic Fan Motor Removal And Installation 943
Hydraulic Fan Motor Disassembly And Assembly 944
Blower Housing Removal And Installation 952
Water Pump Removal And Installation 953
Thermostat Housing Removal And Installation 953
Thermostat – Testing 954
LUBRICATION SYSTEM 955
Description 955
Oil Pan Removal And Installation 956
Oil Pump Removal And Installation 957
Oil Pump Relief Valve Description 958
Oil Suction Pipe Removal And Installation 958
Oil Cooler Removal And Installation 959
Oil Filter Head Removal And Installation 959
Oil Cooler Bypass Description 960
FUEL SYSTEM 961
Description 961
High Pressure Pump Removal And Installation 962
High Pressure Pump Drive Gear Removal And Installation 964
Fuel Temperature Sensor Removal And Installation 964
Fuel Cooler Removal And Installation 965
Fuel Cooler Bypass Valve Removal And Installation 965
Fuel Recirculation Valve Removal And Installation 966
Fuel Rail Assembly Removal And Installation 967
Fuel Injector Removal And Installation 968
Injector Coding 970
Removing Air From The Fuel System 972
CYLINDER HEAD 975
Intake Air Heater Removal And Installation 975
Intake Air Heater Tube Removal And Installation 976
Valve Clearance Adjustment 977
Cylinder Head Removal And Installation 979
Cylinder Head Disassembly And Assembly 982
Cylinder Head Inspection 983
Cylinder Head Top Clearance 984
Valve Step Height 985
Valve Stem Height 985
Valve Guide 986
Valve 986
Valve Spring 987
Rocker Arm Shaft Disassembly And Assembly 988
Rocker Arm Shaft Inspection 989
Push Rod Inspection 989
CRANKSHAFT AND PISTONS 991
Piston And Connecting Rod Removal And Installation 991
Piston And Connecting Rod Inspection 992
Timing Wheel Removal And Installation 994
Crankshaft Removal And Installation 996
Cylinder Block Inspection 998
Crankshaft Inspection 1000
Connecting Rod Inspection 1000
Engine Component Class 1001
CAMSHAFT 1003
Removal And Installation 1003
Inspecting 1004
GEARCASE 1007
Gear Backlash 1007
Gear End Play 1007
Gear Timing 1008
Idle Gear Removal And Installation 1009
Idle Gear Inspection 1009
TURBOCHARGER 1011
Description 1011
Removal And Installation 1011
Testing 1013
FLYWHEEL AND HOUSING 1015
Flywheel Removal And Installation 1015
Ring Gear Removal And Installation 1015
Housing Removal And Installation 1016
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 1017
Description 1017
Removal And Installation 1018
DIESEL EXHAUST FLUID (DEF) / ADBLUE® SYSTEM 1021
Description 1021
Filling The DEF / AdBlue® Tank 1021
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1023
AIR CONDITIONING SYSTEM FLOW 1025
Description 1025
AC System Diagram 1026
Components 1027
Safety Equipment 1030
REGULAR MAINTENANCE 1031
Filters 1031
Compressor Drive Belt Adjustment 1032
Compressor Drive Belt Replacement 1032
Air Conditioning Condenser 1033
Air Conditioning Lubrication 1033
Air Conditioning Service Chart 1034
Evaporator / Heater Coil 1035
TROUBLESHOOTING 1037
Blower Motor Does Not Operate 1037
Blower Motor Operates Normally, But Air Flow Is Insufficient 1037
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal 1037
The Compressor Does Not Operate At All, Or Operates Improperly 1037
Gauge Pressure Related Troubleshooting 1038
Troubleshooting Tree 1040
Temperature / Pressure Chart 1043
Poor A/C Performance 1044
HVAC Repair And Leaks 1045
Electrical System 1046
Engine Coolant Bypassing The Heater Valve 1052
Heater Valve Not Opening Or Closing 1053
SYSTEM CHARGING AND RECLAMATION 1055
Refrigerant Identification 1055
Reclamation And Charging With Recovery / Charging Unit 1056
COMPRESSOR 1059
Removal And Installation 1059
Oil 1061
Oil Check 1062
CONDENSER 1063
Removal And Installation 1063
RECEIVER / DRIER 1065
Receiver / Drier Removal And Installation 1065
Pressure Switch Removal And Installation 1067
Schrader® Valve Removal And Installation 1068
EVAPORATOR / HEATER UNIT 1069
Removal And Installation 1069
THERMOSTAT 1071
Description 1071
Removal And Installation 1072
EXPANSION VALVE 1073
Removal And Installation 1073
EVAPORATOR COIL 1075
Removal And Installation 1075
HEATER COIL 1077
Removal And Installation 1077
BLOWER FAN 1079
Removal And Installation 1079
Disassembly And Assembly 1079
HEATER VALVE 1083
Removal And Installation 1083
EVAPORATOR / HEATER COVER 1085
Removal 1085
Installation 1085
SPECIFICATIONS 1087
LOADER SPECIFICATIONS 1089
Machine Dimensions 1089
Performance 1090
Engine (AJ9C11001 & Above And B3BY11001 & Above) 1090
Engine (B47711001 & Above) 1091
Drive System 1092
Controls 1092
Hydraulic System 1093
Electrical System 1094
Capacities 1094
Tires 1095
TECHNICAL SERVICE GUIDE SPECIFICATIONS 1097
Engine 1097
Engine Torques 1097
Cooling System 1097
Loader Torques 1098
Hydraulic / Hydrostatic System 1098
Fuel Consumption 1098
TORQUE SPECIFICATIONS FOR BOLTS 1099
Torque For General SAE Bolts 1099
Torque For General Metric Bolts 1100
HYDRAULIC CONNECTION SPECIFICATIONS 1101
Straight Thread O-ring Fitting 1101
Flare Fitting 1102
Tubelines And Hoses 1102
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS 1103
Specifications 1103
CONVERSIONS 1105
Decimal And Millimeter Equivalent Chart 1105
U S To Metric Conversion Chart 1105
SERVICE TOOLS REQUIRED 1107
Remote Start Tools 1107
Hydraulic Tools 1108
Mainframe And Drive Tools 1111
Electrical Tools 1114
Engine Tools 1115
HVAC Tools 1120
ALPHABETICAL INDEX 1121

IMAGES PREVIEW OF THE MANUAL:

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PLEASE NOTE:

• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
• The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
• Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer

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