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Bobcat T62 Compact Track Loader Service Manual SN B4SF11001 & Above – PDF DOWNLOAD
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Bobcat T62 Compact Track Loader Service Manual SN B4SF11001 & Above – PDF DOWNLOAD
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Description
Bobcat T62 Compact Track Loader Service Manual SN B4SF11001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat T62 Compact Track Loader Service Manual SN B4SF11001 & Above – PDF DOWNLOAD
Language : English
Pages : 912
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T62 Compact Track Loader Service Manual SN B4SF11001 & Above – PDF DOWNLOAD
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:
1. Check that the ROPS / FOPS (Including side screens) is in good condition and is not modified.
2. Check that ROPS mounting hardware is tightened and is Bobcat approved.
3. The seat belt must be correctly installed, functional and in good condition.
4. The seat bar must be correctly adjusted, clean and lubricated.
5. Check lift arm support device, replace if damaged.
6. Machine signs (decals) must be legible and in the correct location.
7. Steering levers, hand controls and foot pedals must return to neutral (as applicable).
8. Check for correct function of the work lights.
9. The parking brake must function correctly.
10. Enclosure door latches must open and close freely.
11. Bob-Tach® attachment mounting system wedges and linkages must function correctly and be in good condition.
12. Safety treads must be in good condition.
13. Check for correct function of indicator lamps.
14. Check all machine fluid levels.
15. Inspect for fuel, oil or hydraulic fluid leaks.
SAFETY INSTRUCTIONS:
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
• The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
• The AEM Safety Manual delivered with the machine gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Bobcat T62 Compact Track Loader Service Manual SN B4SF11001 & Above – 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 Machine Serial Number Location................................................... 15 Engine Serial Number Location.................................................... 15 DELIVERY REPORT...................................................................... 16 LOADER IDENTIFICATION................................................................ 17 SAFETY & MAINTENANCE..................................................................... 19 LIFTING AND BLOCKING THE LOADER...................................................... 23 Procedure........................................................................ 23 LIFT ARM SUPPORT..................................................................... 25 Lift Arm Support Description..................................................... 25 Installing Lift Arm Support...................................................... 25 Removing Lift Arm Support........................................................ 27 OPERATOR CAB......................................................................... 29 Inspecting Operator Cab.......................................................... 29 Cab Door Sensor Description...................................................... 29 Raising Operator Cab............................................................. 30 Lowering Operator Cab............................................................ 31 Clear Side Enclosed Cab Option................................................... 33 Option........................................................................... 33 Special Applications Kit......................................................... 33 Inspecting And Maintaining Special Applications Kit.............................. 34 Forestry Door And Window Kit..................................................... 34 Inspecting And Maintaining Forestry Door And Window Kit.......................... 34 TRANSPORTING THE LOADER ON A TRAILER................................................. 35 Loading And Unloading Machine.................................................... 35 Fastening Machine To Transport Vehicle........................................... 36 TOWING THE LOADER.................................................................... 37 Procedure........................................................................ 37 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....................................... 39 Description...................................................................... 39 Remote Start Tool (Service Tool) - 7022042....................................... 40 Loader Service Tool Harness - 6689747............................................ 41 Computer Service Tool Harness - 6689746.......................................... 42 Remote Start Procedure........................................................... 43 SERVICE SCHEDULE..................................................................... 47 Maintenance Intervals............................................................ 47 SERVICE SCHEDULE..................................................................... 49 ENGINE AIR CLEANER................................................................... 51 Replacing Engine Air Filter Element (Outer)...................................... 51 Replacing Engine Air Filter Element (Inner)...................................... 52 ENGINE COOLING SYSTEM................................................................ 53 Cleaning Engine Cooling System................................................... 53 Checking And Adding Coolant...................................................... 55 Replacing Coolant................................................................ 56 FUEL SYSTEM.......................................................................... 59 Fuel Specifications.............................................................. 59 Biodiesel Blend Fuel............................................................. 59 Filling The Fuel Tank............................................................ 60 Removing Water From Main Fuel Filter............................................. 61 Replacing Fuel Pre-Filter........................................................ 62 Replacing Main Fuel Filter....................................................... 63 Replacing Fuel Tank Vent Filter.................................................. 65 ENGINE LUBRICATION SYSTEM............................................................ 67 Checking And Adding Engine Oil................................................... 67 Engine Oil Chart................................................................. 67 Replacing Engine Oil And Filter.................................................. 68 HYDRAULIC SYSTEM..................................................................... 71 Checking And Adding Hydraulic Fluid.............................................. 71 Hydraulic Fluid Chart............................................................ 72 Replacing Hydraulic Fluid........................................................ 73 Replacing Main Hydraulic Filter.................................................. 77 Replacing Hydraulic Case Drain Filter............................................ 79 Replacing Hydraulic Charge Filter................................................ 80 Replacing Hydraulic Reservoir Vent Filter........................................ 82 BOB-TACH (HAND LEVER)................................................................ 83 Inspecting And Maintaining Hand Lever Bob-Tach................................... 83 BOB-TACH (POWER)..................................................................... 85 Inspecting And Maintaining Power Bob-Tach........................................ 85 LUBRICATING THE LOADER............................................................... 87 Lubricating Grease Fittings...................................................... 87 PIVOT PINS........................................................................... 89 Checking Pivot Pin Torque........................................................ 89 LOADER STORAGE AND RETURN TO SERVICE................................................. 91 Loader Extended Storage Procedure................................................ 91 Loader Return To Service Procedure............................................... 91 STOPPING THE ENGINE AND LEAVING THE MACHINE.......................................... 93 EMERGENCY EXITS...................................................................... 95 Removing Rear Window With Latches................................................ 95 Removing Rear Window With Rubber Cord............................................ 95 Removing Rear Window With Latches From Outside Loader............................ 96 Removing Rear Window With Rubber Cord From Outside Loader........................ 97 Removing Front Door.............................................................. 97 Front Door Reassembly............................................................ 98 SEAT BELT............................................................................ 99 Inspection And Maintenance....................................................... 99 HYDRAULIC SYSTEM.........................................................................101 HYDRAULIC / HYDROSTATIC SCHEMATICS...................................................105 HYDRAULIC SYSTEM INFORMATION.........................................................113 Glossary Of Hydraulic Symbols....................................................113 Troubleshooting..................................................................117 CYLINDER (LIFT)......................................................................119 Testing..........................................................................119 Removal And Installation.........................................................120 Parts Identification.............................................................124 Disassembly......................................................................125 Assembly.........................................................................128 CYLINDER (TILT)......................................................................133 Testing..........................................................................133 Removal And Installation.........................................................134 Base End Pivot Pin Removal And Installation......................................136 Parts Identification.............................................................137 Disassembly......................................................................138 Assembly.........................................................................141 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 Removal And Installation.......................................156 HYDRAULIC CONTROL VALVE..............................................................157 Description......................................................................157 Removal And Installation.........................................................157 Actuator Removal And Installation................................................162 Identification Chart.............................................................165 Lift Load Check Valve Removal And Installation...................................166 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....................................................171 End Cap Block Removal And Installation...........................................172 Lift Spool Removal And Installation..............................................172 Lift Spool Disassembly And Assembly..............................................174 Tilt Spool Removal And Installation..............................................175 Tilt Spool Disassembly And Assembly..............................................176 Auxiliary Spool Removal And Installation.........................................177 Solenoid Removal And Installation................................................178 Solenoid Removal And Installation................................................179 BICS™ Lock Valve Removal And Installation........................................179 Lift Arm Bypass Orifice Removal And Installation.................................181 Main Relief Valve Removal And Installation.......................................181 Screen Fitting Removal And Installation..........................................182 LIFT ARM BYPASS CONTROL VALVE........................................................183 Description......................................................................183 Testing..........................................................................183 Removal And Installation.........................................................184 Bracket Removal And Installation.................................................185 Disassembly And Assembly.........................................................185 HYDRAULIC PUMP.......................................................................187 Description......................................................................187 Pump Test At Quick Couplers......................................................188 Direct Pump Test (Standard Section)..............................................189 Direct Pump Test (Charge Section)................................................191 Removal And Installation.........................................................193 Hydraulic Pump Startup...........................................................196 Parts Identification.............................................................197 Disassembly And Assembly.........................................................198 HYDRAULIC PUMP (HIGH FLOW)...........................................................199 Description......................................................................199 Direct Pump Test (Standard Section)..............................................201 Direct Pump Test (Charge Section)................................................202 Direct Pump Test (High Flow Section).............................................204 High Flow Relief Valve Adjustment................................................206 High Flow Relief Valve Removal And Installation..................................207 Solenoid Removal And Installation................................................208 Removal And Installation.........................................................209 Hydraulic Pump Startup...........................................................211 Parts Identification.............................................................212 Disassembly And Assembly.........................................................213 HYDRAULIC FILTERS....................................................................215 Description......................................................................215 Housing Removal And Installation.................................................215 HYDRAULIC FLUID RESERVOIR............................................................217 Description......................................................................217 Removal And Installation.........................................................218 OIL COOLER...........................................................................221 Description......................................................................221 Removal And Installation.........................................................221 BUCKET POSITION SENSORS..............................................................223 Description......................................................................223 Removal And Installation.........................................................223 REAR AUXILIARY DIVERTER VALVE........................................................225 Description......................................................................225 Removal And Installation.........................................................225 Disassembly And Assembly.........................................................228 BOB-TACH (POWER) BLOCK...............................................................233 Description......................................................................233 Testing Relief Valve.............................................................234 Removal And Installation.........................................................236 Disassembly And Assembly.........................................................238 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK..............................................243 Description......................................................................243 Removal And Installation.........................................................244 Disassembly And Assembly.........................................................245 AUTOMATIC RIDE CONTROL...............................................................247 Description......................................................................247 Removal And Installation.........................................................248 Checking The Pressure In The Accumulator.........................................250 Adding Nitrogen To The Accumulator...............................................252 HYDROSTATIC SYSTEM.......................................................................255 HYDROSTATIC SYSTEM INFORMATION.......................................................257 Description......................................................................257 Troubleshooting..................................................................257 HYDROSTATIC DRIVE MOTOR..............................................................259 Description......................................................................259 Removing And Replacing Fluid.....................................................259 Removal And Installation.........................................................260 Parts Identification (MCR5T) (One-Speed).........................................263 Parts Identification (MCR6T) (Two-Speed).........................................264 Disassembly And Assembly.........................................................265 CHARGE PRESSURE......................................................................275 Description......................................................................275 Testing..........................................................................275 Sender Removal And Installation..................................................276 Adjusting And Inspecting (SJC)...................................................277 HYDROSTATIC PUMP (MANUAL)............................................................279 Description......................................................................279 Port Locations And Gauge Installation............................................280 Removal And Installation.........................................................281 Hydrostatic Pump Startup.........................................................283 Disassembly And Assembly.........................................................284 HYDROSTATIC PUMP (SJC)...............................................................293 Description......................................................................293 Port Locations And Gauge Installation............................................294 Removal And Installation.........................................................295 Hydrostatic Pump Startup.........................................................298 High Pressure Relief And Bypass Valve............................................300 Charge Pressure Relief Valve.....................................................301 Disassembly And Assembly.........................................................302 Mechanical Neutral Adjustment....................................................313 Hydraulic Controller Neutral Adjustment..........................................315 TWO-SPEED / BRAKE VALVE..............................................................317 Description......................................................................317 Valve Block Removal And Installation.............................................318 Valve Block Disassembly And Assembly.............................................320 DRAIN MANIFOLD.......................................................................323 Description......................................................................323 Drain Manifold Housing Removal And Installation..................................323 DRIVE SYSTEM.............................................................................325 BRAKE................................................................................327 Description......................................................................327 Block Removal And Installation...................................................327 Block Disassembly And Assembly...................................................329 BRAKE (TWO-SPEED)....................................................................331 Description......................................................................331 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED).......................................333 Description......................................................................333 Checking Tension.................................................................334 Adjusting Tension................................................................335 Track Removal And Installation...................................................337 Idler (Front) Removal And Installation...........................................340 Track Tensioner Removal And Installation.........................................341 Track Tensioner Disassembly And Assembly.........................................342 Idler (Rear) Removal And Installation............................................344 Roller Removal And Installation..................................................344 Sprocket Removal And Installation................................................345 Track Frame Removal And Installation.............................................346 TRACK UNDERCARRIAGE COMPONENTS (TORSION SUSPENSION)..................................347 Description......................................................................347 Checking Tension.................................................................349 Adjusting Tension................................................................350 Track Removal And Installation...................................................352 Idler (Front) Removal And Installation...........................................355 Track Tensioner Removal And Installation.........................................356 Track Tensioner Disassembly And Assembly.........................................357 Idler (Rear) Removal And Installation............................................359 Roller Removal And Installation..................................................359 Sprocket Removal And Installation................................................360 Track Frame Removal And Installation.............................................361 TRACK MAINTENANCE....................................................................365 Track Damage Identification......................................................365 MAINFRAME................................................................................377 SEAT BAR.............................................................................381 Description......................................................................381 Removal And Installation.........................................................382 Disassembly And Assembly.........................................................383 Compression Spring Disassembly And Assembly......................................384 OPERATOR CAB.........................................................................385 Gas Spring Removal And Installation..............................................385 Gas Spring Bracket Disassembly And Assembly......................................386 Removal And Installation.........................................................387 OPERATOR SEAT........................................................................389 Removal And Installation.........................................................389 Seat Belt Removal And Installation (Two Point)...................................389 Seat Belt Removal And Installation (Three Point).................................390 OPERATOR SEAT (SUSPENSION)...........................................................393 Removal And Installation.........................................................393 Slide Rail Removal And Installation..............................................393 Seat Belt Removal And Installation...............................................394 Lower Cushion Removal............................................................394 Lower Cushion Installation.......................................................395 Back Cushion Removal And Installation............................................395 Shock Removal And Installation...................................................396 3-Point Seat Belt Removal And Installation.......................................396 BOB-TACH (HAND LEVER)................................................................399 Description......................................................................399 Removal And Installation.........................................................399 Lever And Wedge Disassembly And Assembly.........................................401 Pivot Pin Bushing And Seal Removal And Installation..............................403 BOB-TACH (POWER).....................................................................405 Description......................................................................405 Removal And Installation.........................................................405 Lever And Wedge Disassembly And Assembly.........................................408 Pivot Pin Bushing And Seal Removal And Installation..............................409 LIFT ARMS............................................................................411 Lift Arm Removal And Installation................................................411 REAR GRILLE..........................................................................415 Raising Rear Grille..............................................................415 Lowering Rear Grille.............................................................416 Shield Removal And Installation..................................................416 REAR DOOR (TAILGATE).................................................................417 Removal And Installation.........................................................417 Striker Removal And Installation.................................................418 Striker Disassembly And Assembly.................................................418 Striker (Adjusting)..............................................................419 Latch Removal And Installation...................................................419 FUEL TANK............................................................................421 Removal And Installation.........................................................421 Fuel Level Sender Removal And Installation.......................................423 Fuel Tank Vent Removal And Installation..........................................424 CONTROL PEDALS (MANUAL)..............................................................425 Description......................................................................425 Pedal Removal And Installation (Right Side)......................................425 Pedal Removal And Installation (Left Side).......................................426 Pedal (Adjusting)................................................................426 FOOTREST (SJC).......................................................................427 Footrest Removal And Installation (Right Side)...................................427 Footrest Removal And Installation (Left Side)....................................427 CONTROL LEVER ASSEMBLY...............................................................429 Description......................................................................429 Linkage Removal And Installation.................................................430 Removal And Installation.........................................................431 Disassembly And Assembly.........................................................433 CONTROL LEVER CENTERING ASSEMBLY.....................................................435 Description......................................................................435 Disassembly And Assembly.........................................................436 Linkage Neutral (Adjusting)......................................................440 Linkage Travel (Adjusting).......................................................443 Shock Removal And Installation...................................................447 CONTROL HANDLE / LEVER (MANUAL)......................................................449 Description......................................................................449 Lever Removal And Installation...................................................450 CONTROL HANDLE (SJC).................................................................451 Description......................................................................451 Joystick Testing.................................................................451 Joystick Removal And Installation................................................452 ACCESS PANELS (LOWER)................................................................455 Removal And Installation (Left Side).............................................455 Removal And Installation (Right Side)............................................457 ACCESS PANELS (UPPER)................................................................459 Removal And Installation (Center Panel)..........................................459 Removal And Installation (Left Side).............................................460 Removal And Installation (Right Side)............................................461 WINDOW (REAR)........................................................................463 Removing Rear Window With Latches................................................463 Removing Rear Window With Rubber Cord............................................463 Removing Rear Window With Latches From Outside Loader............................464 Removing Rear Window With Latches From Outside Loader With Knob Kit..............464 Removing Rear Window With Rubber Cord From Outside Loader........................464 Disassembly And Assembly (Latches)...............................................465 Removal (Rubber Cord)............................................................466 Installation (Rubber Cord).......................................................467 WINDOW (TOP).........................................................................469 Removal And Installation.........................................................469 WINDOW (SIDE)........................................................................471 Removal And Installation.........................................................471 CAB DOOR.............................................................................473 Description......................................................................473 Removal And Installation.........................................................473 Disassembly And Assembly.........................................................474 Aligning.........................................................................476 Adjusting........................................................................476 Checking Operation...............................................................477 ARMREST..............................................................................479 Description......................................................................479 Removal And Installation.........................................................480 Disassembly And Assembly.........................................................482 HEADLINER............................................................................485 Removal And Installation.........................................................485 ELECTRICAL SYSTEM........................................................................489 ELECTRICAL SCHEMATICS................................................................493 ELECTRICAL SYSTEM....................................................................517 Glossary Of Electrical Symbols...................................................517 Standard Cab Harness Connectors..................................................520 Deluxe Cab Harness Connectors....................................................521 Mainframe Harness Connectors.....................................................522 Electrical System Description....................................................523 Fuse And Relay Identification....................................................524 Solenoid Testing.................................................................528 BATTERY..............................................................................529 Removing And Installing Battery..................................................529 Battery Maintenance..............................................................530 Maintaining Battery Charge Level.................................................530 Battery Service During Machine Storage...........................................530 Testing Battery..................................................................531 Charging Battery.................................................................531 Using A Booster Battery (Jump Starting)..........................................532 ALTERNATOR...........................................................................533 Adjusting Belt (Machines Without Air Conditioning)...............................533 Replacing Belt (Machines Without Air Conditioning)...............................533 Adjusting Belt (Machines With Air Conditioning)..................................534 Replacing Belt (Machines With Air Conditioning)..................................534 Charging System Inspection.......................................................535 Alternator Voltage Testing.......................................................536 Low Voltage Testing..............................................................537 High Voltage Testing.............................................................537 Removal And Installation (Machines Without Air Conditioning).....................538 Removal And Installation (Machines With Air Conditioning)........................539 Parts Identification.............................................................540 STARTER..............................................................................541 Testing..........................................................................541 Removal And Installation.........................................................541 Parts Identification.............................................................542 INSTRUMENT PANEL IDENTIFICATION......................................................543 Instrument Panel Overview........................................................543 Standard Display.................................................................544 Touch Display....................................................................546 Left Control Panel...............................................................548 Right Control Panel..............................................................548 Jog Shuttle (Standard Display)...................................................549 Jog Shuttle (Touch Display)......................................................549 Heating, Ventilation, And Air Conditioning (HVAC) Controls.......................550 Touch Display Radio Input Ports..................................................550 Keyed Ignition Kit...............................................................551 Radio Identification.............................................................552 Left Switch Panel Removal And Installation.......................................554 Right Switch Panel Removal And Installation......................................555 LIGHTS...............................................................................557 Front Removal And Installation...................................................557 Rear Removal And Installation....................................................557 Cab Light Removal And Installation...............................................558 Side Light Removal And Installation..............................................558 BOBCAT HUB CONTROLLER................................................................559 Description......................................................................559 Connector Identification.........................................................560 Removal And Installation.........................................................563 BOBCAT MID CONTROLLER................................................................565 Description......................................................................565 Removal And Installation.........................................................566 BOBCAT CONTROLLER (SJC) (DRIVE)......................................................567 Description......................................................................567 Removal And Installation.........................................................568 ENGINE CONTROL UNIT (ECU)............................................................569 Description......................................................................569 Cleaning.........................................................................570 Removal And Installation.........................................................571 DIAGNOSTIC SERVICE CODES.............................................................573 Service Codes List...............................................................573 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..............................................579 Inspecting The Bobcat Interlock Control System (BICS™)...........................579 Inspecting The Lift Arm Bypass Control...........................................581 SEAT BAR SENSOR......................................................................583 Description......................................................................583 Troubleshooting..................................................................583 Testing..........................................................................584 Removal And Installation.........................................................585 Bobcat Interlock Control System (BICS™) Circuit Test.............................588 TRACTION LOCK........................................................................591 Description......................................................................591 Troubleshooting..................................................................592 Operating Parking Brake..........................................................593 Operating Hydraulic Controls With Parking Brake Engaged..........................593 CONTROL IDENTIFICATION...............................................................595 Identification Chart (Standard)..................................................595 Identification Chart (SJC).......................................................596 SERVICE PC (LAPTOP COMPUTER).........................................................597 Connecting Remote Start Tool (Service Tool)......................................597 CALIBRATION..........................................................................599 Description......................................................................599 Actuator Testing.................................................................599 Lift And Tilt Calibration (SJC)..................................................602 Adjusting Lift And Tilt Compensation.............................................602 Hydrostatic Pump Calibration (SJC)...............................................605 STEERING DRIFT COMPENSATION..........................................................611 Steering Drift Compensation Description..........................................611 Adjusting Steering Drift Compensation............................................612 NAVIGATION (STANDARD DISPLAY)........................................................615 Navigation Bar...................................................................615 Viewing Active Shortcuts.........................................................615 VITALS (STANDARD DISPLAY)............................................................617 Vital Detail And Machine Performance.............................................617 SERVICE (STANDARD DISPLAY)...........................................................619 Record A Service.................................................................619 SETTINGS (STANDARD DISPLAY)..........................................................621 Display Settings.................................................................621 Machine Settings.................................................................622 Language Settings................................................................623 Units............................................................................624 Software.........................................................................625 GAUGES (TOUCH DISPLAY)...............................................................627 Vital Detail And Machine Performance.............................................627 Notification Drawer..............................................................628 CAMERA (TOUCH DISPLAY)...............................................................629 Camera Settings..................................................................629 PHONE (TOUCH DISPLAY)................................................................631 AUDIO (TOUCH DISPLAY)................................................................633 SERVICE (TOUCH DISPLAY)..............................................................635 Record A Service.................................................................635 View Service Schedule............................................................636 View Service Record..............................................................637 View Service Codes...............................................................638 ATTACHMENTS (TOUCH DISPLAY)..........................................................639 Attachment Information...........................................................639 SETTINGS (TOUCH DISPLAY).............................................................641 Favorites........................................................................641 Display Settings.................................................................643 Machine Settings.................................................................644 Security Settings................................................................645 Security Settings (Manage Operators).............................................646 Operator Statistics..............................................................650 Job Clocks.......................................................................651 Language Settings................................................................653 Units............................................................................654 Camera Settings..................................................................654 Bluetooth® Settings..............................................................654 Audio Settings...................................................................654 Dealer...........................................................................655 Software.........................................................................656 PASSWORD SETUP.......................................................................657 Security Settings................................................................657 Security Settings (Manage Operators).............................................658 MAINTENANCE CLOCK....................................................................659 Record A Service.................................................................659 View Service Codes...............................................................660 BACK-UP ALARM SYSTEM.................................................................661 Inspecting Back-Up Alarm System..................................................661 Troubleshooting (Joystick).......................................................662 Alarm Removal And Installation...................................................663 FRONT HORN...........................................................................665 Removal And Installation.........................................................665 Troubleshooting..................................................................666 ENGINE SPEED CONTROL (HAND)..........................................................667 Description......................................................................667 Removal And Installation.........................................................668 ENGINE SPEED CONTROL (FOOT)..........................................................669 Description......................................................................669 Removal And Installation.........................................................669 Disassembly And Assembly.........................................................670 CAMSHAFT AND CRANKSHAFT POSITION SENSOR..............................................673 Removal And Installation.........................................................673 MACHINE IQ...........................................................................675 Description......................................................................675 Removal And Installation.........................................................675 Procedure........................................................................676 ENGINE SERVICE...........................................................................677 ENGINE INFORMATION...................................................................681 Description......................................................................681 Specifications...................................................................682 Sensor Location..................................................................684 Torque Values....................................................................691 Troubleshooting..................................................................693 Engine Removal And Installation..................................................695 Engine Mount Replacement.........................................................701 Compression - Testing............................................................703 Injector Signal - Testing........................................................705 Oil Pressure Testing (At Turbocharger Oil Inlet).................................707 DIESEL OXIDATION CATALYST (DOC)......................................................709 Removal And Installation.........................................................709 AIR CLEANER..........................................................................711 Housing Removal And Installation.................................................711 ENGINE COOLING SYSTEM................................................................713 Radiator Cooling Package Removal And Installation................................713 Hydraulic Fan Description........................................................717 Reversible Hydraulic Fan Description.............................................717 Hydraulic Fan Motor Assembly Removal And Installation............................718 Hydraulic Fan Motor Removal And Installation.....................................721 Hydraulic Fan Motor Disassembly And Assembly.....................................723 Water Pump Removal And Installation..............................................731 Thermostat Housing Removal And Installation......................................732 Testing The Thermostat...........................................................733 LUBRICATION SYSTEM...................................................................735 Description......................................................................735 Oil Pan Removal And Installation.................................................736 Oil Pump Removal And Installation................................................737 Oil Pump Relief Valve Description................................................738 Oil Pump Relief Valve Removal And Installation...................................738 Oil Cooler Removal And Installation..............................................738 Oil Filter Head Removal And Installation.........................................739 Oil Cooler Bypass Description....................................................741 Oil Cooler Bypass Removal And Installation.......................................741 FUEL SYSTEM..........................................................................743 Fuel Filter Housing Removal And Installation.....................................743 Fuel Lift Pump Removal And Installation..........................................745 Fuel Lift Pump Filter Removal And Installation...................................746 Transfer Pump / High Pressure Pump Removal And Installation......................746 Fuel Temperature Sensor Removal And Installation.................................748 Fuel Recirculation Valve (FRV) Removal And Installation..........................749 Fuel Pressure Relief Valve Removal And Installation..............................749 Fuel Rail Assembly Removal And Installation......................................750 Fuel Injector Removal And Installation...........................................751 Injector Coding..................................................................755 CYLINDER HEAD........................................................................757 Glow Plugs Testing...............................................................757 Glow Plug Removal And Installation...............................................758 Cylinder Head Removal And Installation...........................................759 Cylinder Head Disassembly And Assembly...........................................762 Cylinder Head Inspection.........................................................763 Cylinder Head Top Clearance......................................................764 Valve Step Height................................................................765 Valve Stem Height................................................................765 Valve Guide......................................................................766 Valve............................................................................766 Valve Spring.....................................................................767 Rocker Arm Shaft Disassembly And Assembly........................................768 Rocker Arm Shaft Inspection......................................................769 Push Rod Inspection..............................................................769 CRANKSHAFT AND PISTONS...............................................................771 Piston And Connecting Rod Removal And Installation...............................771 Piston And Connecting Rod Inspection.............................................772 Crankshaft Removal And Installation..............................................774 Cylinder Block Inspection........................................................777 Crankshaft Inspection............................................................779 Connecting Rod Inspection........................................................779 Engine Component Class...........................................................780 CAMSHAFT.............................................................................783 Removal And Installation.........................................................783 Inspecting.......................................................................784 GEARCASE.............................................................................787 Gearcase Cover Removal And Installation..........................................787 Gear Backlash....................................................................788 Gear Timing......................................................................789 Idle Gear Removal And Installation...............................................790 Idle Gear Inspection.............................................................790 TURBOCHARGER.........................................................................791 Description......................................................................791 Removal And Installation.........................................................791 Inspection.......................................................................793 FLYWHEEL AND HOUSING.................................................................795 Flywheel Removal And Installation................................................795 Ring Gear Removal And Installation...............................................796 Housing Removal And Installation.................................................797 EXHAUST GAS RECIRCULATION (EGR) SYSTEM...............................................799 Description......................................................................799 Removal And Installation.........................................................800 EXHAUST MANIFOLD.....................................................................803 Removal And Installation.........................................................803 HEATING, VENTILATION AND AIR CONDITIONING (HVAC).........................................805 AIR CONDITIONING SYSTEM FLOW.........................................................807 Description......................................................................807 Chart............................................................................808 Components.......................................................................809 Safety Equipment.................................................................812 REGULAR MAINTENANCE..................................................................813 Cleaning HVAC Filters............................................................813 Cleaning Air Conditioning Evaporator And Heater Coil.............................814 Cleaning Air Conditioning Condenser..............................................815 Lubricating Air Conditioning System..............................................815 Troubleshooting HVAC System......................................................815 Adjusting Belt...................................................................816 Replacing Belt...................................................................816 Air Conditioning Service Chart...................................................817 TROUBLESHOOTING......................................................................819 Blower Motor Does Not Operate....................................................819 Blower Motor Operates Normally, But Air Flow Is Insufficient.....................819 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal.......819 The Compressor Does Not Operate At All, Or Operates Improperly...................819 Gauge Pressure Related Troubleshooting...........................................820 Troubleshooting Tree.............................................................822 Temperature / Pressure Chart.....................................................826 Poor A/C Performance.............................................................828 HVAC Repair And Leaks............................................................829 Electrical System................................................................830 Engine Coolant Bypassing The Heater Valve........................................836 Heater Valve Not Opening Or Closing..............................................837 SYSTEM CHARGING AND RECLAMATION......................................................839 Refrigerant Identification.......................................................839 Reclamation And Charging With Recovery / Charging Unit...........................840 COMPRESSOR...........................................................................843 Removal And Installation.........................................................843 Oil..............................................................................844 Oil Check........................................................................845 CONDENSER............................................................................847 Removal And Installation.........................................................847 RECEIVER / DRIER.....................................................................849 Receiver / Drier Removal And Installation........................................849 EVAPORATOR / HEATER UNIT.............................................................851 Removal And Installation.........................................................851 THERMOSTAT...........................................................................853 Description......................................................................853 Removal And Installation.........................................................854 EXPANSION VALVE......................................................................857 Removal And Installation.........................................................857 EVAPORATOR COIL......................................................................861 Removal And Installation.........................................................861 HEATER COIL..........................................................................865 Removal And Installation.........................................................865 BLOWER FAN...........................................................................867 Removal And Installation.........................................................867 Disassembly And Assembly.........................................................868 HEATER VALVE.........................................................................871 Removal And Installation.........................................................871 EVAPORATOR / HEATER COVER............................................................873 Removing.........................................................................873 Installing.......................................................................874 SPECIFICATIONS...........................................................................875 LOADER SPECIFICATIONS................................................................877 Machine Dimensions...............................................................877 Performance Specifications.......................................................879 Engine Specifications............................................................879 Drive System Specifications......................................................880 Control Specifications...........................................................880 Hydraulic System Specifications..................................................881 Hydraulic Cylinder Specifications................................................881 Electrical System Specifications.................................................882 Fluid Capacities.................................................................882 Tracks...........................................................................882 Ground Pressure..................................................................882 TECHINCAL SERVICE GUIDE SPECIFICATIONS...............................................883 Engine...........................................................................883 Engine Torques...................................................................883 Cooling System...................................................................883 Loader Torques...................................................................884 Hydraulic / Hydrostatic System...................................................884 Fuel Consumption.................................................................884 TORQUE SPECIFICATIONS FOR BOLTS......................................................885 Torque For General SAE Bolts.....................................................885 Torque For General Metric Bolts..................................................886 HYDRAULIC CONNECTION SPECIFICATIONS..................................................887 Straight Thread O-ring Fitting...................................................887 Flare Fitting....................................................................888 Tubelines And Hoses..............................................................888 HYDRAULIC FLUID SPECIFICATIONS.......................................................889 Specifications...................................................................889 CONVERSIONS..........................................................................891 Decimal And Millimeter Equivalent Chart..........................................891 U.S. To Metric Conversion Chart..................................................891 SERVICE TOOLS REQUIRED...............................................................893 Remote Start Tools...............................................................893 Hydraulic Tools..................................................................894 Mainframe And Drive Tools........................................................897 Electrical Tools.................................................................900 Engine Tools.....................................................................901 HVAC Tools.......................................................................906 ALPHABETICAL INDEX.......................................................................907
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