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Bobcat T650 Compact Track Loader Service Manual 6990755 – PDF DOWNLOAD
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Bobcat T650 Compact Track Loader Service Manual 6990755 – PDF DOWNLOAD
S/N ALJG11001 & Above
S/N T1ML11001 & Above
S/N B2KZ11001 & Above
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Description
Bobcat T650 Compact Track Loader Service Manual 6990755 – PDF DOWNLOAD
FILE DETAILS:
Bobcat T650 Compact Track Loader Service Manual 6990755 – PDF DOWNLOAD
Language : English
Pages : 1288
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T650 Compact Track Loader Service Manual 6990755 – PDF DOWNLOAD
S/N ALJG11001 & Above
S/N T1ML11001 & Above
S/N B2KZ11001 & 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:
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.
TABLE OF CONTENTS:
Bobcat T650 Compact Track Loader Service Manual 6990755 – PDF DOWNLOAD
MAINTENANCE SAFETY.................................................................................................................... 3 CONTENTS.............................................................................................................................. 5 FOREWORD.............................................................................................................................. 7 FOREWORD.......................................................................................................................... 9 SAFETY INSTRUCTIONS............................................................................................................... 11 FIRE PREVENTION................................................................................................................... 13 Maintenance................................................................................................................... 13 Operation..................................................................................................................... 13 Electrical.................................................................................................................... 13 Hydraulic System.............................................................................................................. 13 Fueling....................................................................................................................... 13 Starting...................................................................................................................... 13 Spark Arrester Exhaust System................................................................................................. 13 Welding And Grinding.......................................................................................................... 14 Fire Extinguishers............................................................................................................ 14 SERIAL NUMBER LOCATIONS........................................................................................................... 15 Loader Serial Number.......................................................................................................... 15 Engine Serial Number.......................................................................................................... 15 DELIVERY REPORT................................................................................................................... 16 LOADER IDENTIFICATION............................................................................................................. 17 SAFETY & MAINTENANCE.................................................................................................................. 19 LIFTING AND BLOCKING THE LOADER................................................................................................... 23 Procedure..................................................................................................................... 23 LIFT ARM SUPPORT DEVICE........................................................................................................... 25 Description................................................................................................................... 25 Installing.................................................................................................................... 26 Removing...................................................................................................................... 27 OPERATOR CAB...................................................................................................................... 29 Description................................................................................................................... 29 Raising....................................................................................................................... 30 Lowering...................................................................................................................... 31 Cab Door Sensor............................................................................................................... 32 Special Applications Kit...................................................................................................... 33 Special Applications Kit Inspection And Maintenance........................................................................... 33 Forestry Door And Window Kit.................................................................................................. 34 Forestry Door And Window Kit Inspection And Maintenance....................................................................... 34 TRANSPORTING 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................................................................................... 40 Remote Start Procedure........................................................................................................ 41 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666.................................................................................... 45 Description................................................................................................................... 45 Remote Start Tool (Service Tool) - 7022042.................................................................................... 46 Loader Service Tool Harness - 6689747......................................................................................... 47 Computer Service Tool Harness - 6689746....................................................................................... 48 Remote Start Procedure........................................................................................................ 49 SERVICE SCHEDULE.................................................................................................................. 53 Maintenance Intervals......................................................................................................... 53 AIR CLEANER SERVICE............................................................................................................... 55 Replacing Filter Elements..................................................................................................... 55 ENGINE COOLING SYSTEM............................................................................................................. 57 Maintenance Platform.......................................................................................................... 57 Cleaning...................................................................................................................... 57 Checking Level................................................................................................................ 60 Removing And Replacing Coolant................................................................................................ 61 FUEL SYSTEM....................................................................................................................... 63 Fuel Specifications........................................................................................................... 63 Biodiesel Blend Fuel.......................................................................................................... 63 Filling The Fuel Tank......................................................................................................... 64 Fuel Filter................................................................................................................... 65 Removing Air From The Fuel System............................................................................................. 66 ENGINE LUBRICATION SYSTEM......................................................................................................... 67 Checking And Adding Engine Oil................................................................................................ 67 Engine Oil Chart.............................................................................................................. 67 Removing And Replacing Oil And Filter......................................................................................... 68 HYDRAULIC / HYDROSTATIC SYSTEM.................................................................................................... 71 Checking And Adding Fluid..................................................................................................... 71 Hydraulic / Hydrostatic Fluid Chart........................................................................................... 71 Removing And Replacing Hydraulic Fluid........................................................................................ 72 Hydraulic / Hydrostatic Filter Identification................................................................................. 74 Removing And Replacing Hydraulic / Hydrostatic Filter (Earlier Models)........................................................ 75 Removing And Replacing Hydraulic / Hydrostatic Filter (Later Models).......................................................... 76 Removing And Replacing Hydraulic Charge Filter................................................................................ 77 Replacing Reservoir Breather Cap.............................................................................................. 79 BOB-TACH (HAND LEVER)............................................................................................................. 81 Inspection And Maintenance.................................................................................................... 81 BOB-TACH (POWER).................................................................................................................. 83 Inspection And Maintenance.................................................................................................... 83 LUBRICATING THE LOADER............................................................................................................ 85 Lubrication Locations......................................................................................................... 85 Track Roller And Idler Lubrication............................................................................................ 88 PIVOT PINS........................................................................................................................ 89 Inspection And Maintenance.................................................................................................... 89 LOADER STORAGE AND RETURN TO SERVICE.............................................................................................. 91 Storage....................................................................................................................... 91 Return To Service............................................................................................................. 91 STOPPING THE ENGINE AND LEAVING THE LOADER........................................................................................ 93 Procedure..................................................................................................................... 93 EMERGENCY EXIT.................................................................................................................... 95 Rear Window Identification.................................................................................................... 95 Rear Window Removal (Latches)................................................................................................. 95 Rear Window Removal (Rubber Cord)............................................................................................. 95 External Access (Rear Window With Latches).................................................................................... 96 External Access (Rear Window With Rubber Cord)................................................................................ 96 Front Door.................................................................................................................... 96 SEAT BELT......................................................................................................................... 99 Inspection And Maintenance.................................................................................................... 99 HYDRAULIC SYSTEM...................................................................................................................... 101 HYDRAULIC / HYDROSTATIC SCHEMATICS................................................................................................ 107 HYDRAULIC SYSTEM INFORMATION...................................................................................................... 123 Glossary Of Hydraulic / Hydrostatic Symbols................................................................................... 123 Troubleshooting............................................................................................................... 127 CYLINDER (LIFT)................................................................................................................... 129 Testing....................................................................................................................... 129 Removal And Installation...................................................................................................... 130 Parts Identification.......................................................................................................... 134 Disassembly................................................................................................................... 135 Assembly...................................................................................................................... 137 CYLINDER (TILT)................................................................................................................... 141 Testing....................................................................................................................... 141 Removal And Installation...................................................................................................... 142 Base End Pivot Pin Removal And Installation................................................................................... 144 Parts Identification (Earlier Models)......................................................................................... 145 Parts Identification (Later Models)........................................................................................... 146 Disassembly................................................................................................................... 147 Assembly...................................................................................................................... 150 CYLINDER (BOB-TACH)............................................................................................................... 153 Testing....................................................................................................................... 153 Removal And Installation...................................................................................................... 154 Parts Identification.......................................................................................................... 155 Disassembly................................................................................................................... 156 Assembly...................................................................................................................... 157 MAIN RELIEF VALVE................................................................................................................. 161 Description................................................................................................................... 161 Testing....................................................................................................................... 162 Main Relief Valve Adjustment.................................................................................................. 164 Main Relief Valve Removal And Installation.................................................................................... 164 Auxiliary Relief Valve Adjustment............................................................................................. 165 Auxiliary Relief Valve Removal And Installation............................................................................... 166 HYDRAULIC CONTROL VALVE (STANDARD)................................................................................................ 167 Description................................................................................................................... 167 Removal And Installation...................................................................................................... 168 Mount Bracket Removal And Installation........................................................................................ 172 Identification Chart.......................................................................................................... 173 Lift Load Check Valve Removal And Installation................................................................................ 174 Load Check Valve Removal And Installation (Tilt And Auxiliary)................................................................ 175 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)................................................................ 176 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................................................. 176 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................................................. 177 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................................................. 177 Port Relief Valve Removal And Installation.................................................................................... 178 Plug Removal And Installation................................................................................................. 180 Rubber Boot Removal And Installation.......................................................................................... 181 End Cap Block Removal And Installation........................................................................................ 181 Lift Spool And Detent Removal And Installation................................................................................ 182 Tilt Spool Removal And Installation........................................................................................... 190 Auxiliary Spool Removal And Installation...................................................................................... 192 Auxiliary Solenoid Removal And Installation................................................................................... 193 Solenoid Removal And Installation............................................................................................. 194 Lock Valve Removal And Installation........................................................................................... 195 Lift Arm Bypass Orifice Removal And Installation.............................................................................. 197 Main Relief Valve Removal And Installation.................................................................................... 197 Auxiliary Relief Valve Removal And Installation............................................................................... 198 Check Valve Removal And Installation.......................................................................................... 198 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)............................................................................................ 201 Description................................................................................................................... 201 Removal And Installation...................................................................................................... 201 Actuator Removal And Installation (In Loader)................................................................................. 206 Actuator Removal And Installation (Out Of Loader)............................................................................. 207 Identification Chart.......................................................................................................... 210 Mount Bracket Removal And Installation........................................................................................ 211 Lift Load Check Valve Removal And Installation................................................................................ 211 Load Check Valve Removal And Installation (Tilt And Auxiliary)................................................................ 212 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)................................................................ 213 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................................................. 213 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................................................. 214 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................................................. 214 Port Relief Valve Removal And Installation.................................................................................... 215 Plug Removal And Installation................................................................................................. 217 End Cap Block Removal And Installation........................................................................................ 218 Lift Spool Removal And Installation........................................................................................... 218 Lift Spool Disassembly And Assembly........................................................................................... 220 Tilt Spool Removal And Installation........................................................................................... 221 Tilt Spool Disassembly And Assembly........................................................................................... 222 Auxiliary Spool Removal And Installation...................................................................................... 223 Auxiliary Solenoid Removal And Installation................................................................................... 224 Solenoid Removal And Installation............................................................................................. 225 Lock Valve Removal And Installation........................................................................................... 226 Lift Arm Bypass Orifice Removal And Installation.............................................................................. 228 Main Relief Valve Removal And Installation.................................................................................... 228 Auxiliary Relief Valve Removal And Installation............................................................................... 229 Check Valve Removal And Installation.......................................................................................... 229 LIFT ARM BYPASS CONTROL VALVE..................................................................................................... 231 Description................................................................................................................... 231 Removal And Installation...................................................................................................... 232 Bracket Removal And Installation.............................................................................................. 233 Disassembly And Assembly...................................................................................................... 233 HYDRAULIC PUMP.................................................................................................................... 235 Description................................................................................................................... 235 Pump Test At Quick Couplers................................................................................................... 235 Direct Pump Test (Standard Section)........................................................................................... 236 Direct Pump Test (Charge Section)............................................................................................. 238 Removal And Installation...................................................................................................... 240 Hydraulic Pump Startup........................................................................................................ 242 Parts Identification.......................................................................................................... 243 Disassembly And Assembly...................................................................................................... 244 HYDRAULIC PUMP (HIGH FLOW)........................................................................................................ 245 Description................................................................................................................... 245 Pump Test At Quick Couplers................................................................................................... 245 Direct Pump Test (Standard Section)........................................................................................... 246 Direct Pump Test (Charge Section)............................................................................................. 247 Direct Pump Test (High Flow Section).......................................................................................... 250 High Flow Relief Valve Adjustment............................................................................................. 252 High Flow Relief Valve Removal And Installation............................................................................... 253 Solenoid Removal And Installation............................................................................................. 254 Removal And Installation...................................................................................................... 255 Hydraulic Pump Startup........................................................................................................ 257 Parts Identification.......................................................................................................... 258 Disassembly And Assembly...................................................................................................... 259 HYDRAULIC / HYDROSTATIC FILTERS (EARLIER MODELS).................................................................................. 261 Description................................................................................................................... 261 Housing Removal And Installation.............................................................................................. 261 HYDRAULIC / HYDROSTATIC FILTERS (LATER MODELS).................................................................................... 263 Description................................................................................................................... 263 Housing Removal And Installation.............................................................................................. 264 HYDRAULIC FLUID RESERVOIR......................................................................................................... 267 Description................................................................................................................... 267 Removal And Installation...................................................................................................... 267 Hydraulic Fluid Screen........................................................................................................ 268 OIL COOLER........................................................................................................................ 269 Description................................................................................................................... 269 Removal And Installation...................................................................................................... 269 BUCKET POSITION VALVE............................................................................................................. 271 Description................................................................................................................... 271 Solenoid Removal And Installation............................................................................................. 271 Solenoid Testing.............................................................................................................. 272 Removal And Installation...................................................................................................... 272 Disassembly And Assembly...................................................................................................... 275 REAR AUXILIARY DIVERTER VALVE..................................................................................................... 277 Description................................................................................................................... 277 Solenoid Testing.............................................................................................................. 277 Removal And Installation...................................................................................................... 278 Disassembly And Assembly...................................................................................................... 279 BOB-TACH (POWER) BLOCK (S/N ALJG11001 - 13367 AND B2KZ11001 - 11017).............................................................. 285 Description................................................................................................................... 285 Removal And Installation...................................................................................................... 285 Disassembly And Assembly...................................................................................................... 287 BOB-TACH (POWER) BLOCK (S/N ALJG13368 AND B2KZ11018 & ABOVE)...................................................................... 297 Description................................................................................................................... 297 Testing Relief Valve.......................................................................................................... 298 Removal And Installation...................................................................................................... 300 Disassembly And Assembly...................................................................................................... 302 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK........................................................................................... 307 Description................................................................................................................... 307 Removal And Installation...................................................................................................... 308 Disassembly And Assembly (FFI/FI)............................................................................................. 308 Disassembly And Assembly (FFH/FH)............................................................................................. 310 AUTOMATIC RIDE CONTROL............................................................................................................ 313 Description................................................................................................................... 313 Removal And Installation...................................................................................................... 314 Checking The Pressure In The Accumulator...................................................................................... 317 Adding Nitrogen To The Accumulator............................................................................................ 319 HYDROSTATIC SYSTEM.................................................................................................................... 321 HYDROSTATIC SYSTEM INFORMATION.................................................................................................... 323 Description................................................................................................................... 323 Troubleshooting............................................................................................................... 323 HYDROSTATIC DRIVE MOTOR (SIX TRACK SPROCKET NUTS)................................................................................. 325 Description................................................................................................................... 325 Machine Identification........................................................................................................ 326 Removing And Replacing Fluid.................................................................................................. 326 Removal And Installation...................................................................................................... 327 Parts Identification.......................................................................................................... 329 Disassembly And Assembly...................................................................................................... 331 HYDROSTATIC DRIVE MOTOR (EIGHT TRACK SPROCKET NUTS)............................................................................... 345 Description................................................................................................................... 345 Machine Identification........................................................................................................ 346 Removing And Replacing Fluid.................................................................................................. 346 Removal And Installation...................................................................................................... 347 Parts Identification.......................................................................................................... 349 Disassembly And Assembly...................................................................................................... 351 HYDROSTATIC DRIVE MOTOR (SIXTEEN TRACK SPROCKET BOLTS)............................................................................ 365 Description................................................................................................................... 365 Machine Identification........................................................................................................ 366 Removing And Replacing Fluid.................................................................................................. 366 Removal And Installation...................................................................................................... 367 Parts Identification (Single Speed)........................................................................................... 369 Parts Identification (MCR6T) (Two-Speed)...................................................................................... 370 Disassembly And Assembly...................................................................................................... 371 CHARGE PRESSURE................................................................................................................... 381 Description................................................................................................................... 381 Testing....................................................................................................................... 381 Sender Removal And Installation (Earlier Models).............................................................................. 383 Sender Removal And Installation (Later Models)................................................................................ 383 Adjusting..................................................................................................................... 384 HYDROSTATIC PUMP.................................................................................................................. 387 Description................................................................................................................... 387 Removal And Installation...................................................................................................... 388 Hydrostatic Pump Startup...................................................................................................... 389 Replenishing / High Pressure Relief Valve Removal And Installation............................................................ 389 Parts Identification (Left Half).............................................................................................. 390 Parts Identification (Right Half)............................................................................................. 391 Disassembly................................................................................................................... 392 Assembly...................................................................................................................... 399 HYDROSTATIC PUMP (SJC)............................................................................................................ 407 Description................................................................................................................... 407 Hydraulic Controller Removal And Installation................................................................................. 408 Removal And Installation...................................................................................................... 410 Hydrostatic Pump Startup...................................................................................................... 411 Parts Identification.......................................................................................................... 412 High Pressure Relief And Bypass Valve......................................................................................... 413 Charge Relief Valve........................................................................................................... 414 Disassembly And Assembly...................................................................................................... 415 Mechanical Neutral Adjustment................................................................................................. 428 Hydraulic Controller Neutral Adjustment....................................................................................... 431 DRIVE BELT........................................................................................................................ 435 Belt Adjustment............................................................................................................... 435 Stop Adjustment............................................................................................................... 435 Belt Replacement.............................................................................................................. 436 Tensioner Pulley Removal And Installation (Earlier Models).................................................................... 438 Tensioner Pulley Disassembly And Assembly..................................................................................... 438 Tensioner Pulley Removal And Installation (Later Models)...................................................................... 439 Tensioner Pulley Disassembly And Assembly..................................................................................... 439 TWO-SPEED / BRAKE VALVE........................................................................................................... 441 Description................................................................................................................... 441 Valve Block Removal And Installation.......................................................................................... 442 Valve Block Disassembly And Assembly.......................................................................................... 444 DRAIN MANIFOLD.................................................................................................................... 447 Description................................................................................................................... 447 Drain Manifold Removal And Installation....................................................................................... 448 DRIVE SYSTEM.......................................................................................................................... 449 BRAKE............................................................................................................................. 451 Description................................................................................................................... 451 Block Removal And Installation................................................................................................ 451 Block Disassembly And Assembly................................................................................................ 453 BRAKE (TWO-SPEED)................................................................................................................. 455 Description................................................................................................................... 455 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) (S/N ALJG11001 - ALJG15999 AND B2KZ11001 - B2KZ11999 AND T1ML11001 & ABOVE)........ 457 Description................................................................................................................... 457 Checking Tension.............................................................................................................. 458 Adjusting Tension............................................................................................................. 459 Track Removal And Installation................................................................................................ 460 Idler (Front) Removal And Installation........................................................................................ 462 Track Tensioner Disassembly And Assembly...................................................................................... 465 Idler (Rear) Removal And Installation......................................................................................... 467 Roller Removal And Installation............................................................................................... 467 Sprocket Removal And Installation (Single Speed).............................................................................. 468 Sprocket Removal And Installation (Two-Speed)................................................................................. 468 Track Housing Removal And Installation........................................................................................ 469 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) (S/N ALJG11001 - ALJG15999 AND B2KZ11001 - B2KZ11999 AND T1ML11001 & ABOVE).... 471 Description................................................................................................................... 471 Checking Tension.............................................................................................................. 472 Adjusting Tension............................................................................................................. 473 Track Removal And Installation................................................................................................ 474 Idler (Front) Removal And Installation........................................................................................ 476 Track Tensioner Disassembly And Assembly...................................................................................... 479 Idler (Rear) Removal And Installation......................................................................................... 481 Roller Removal And Installation............................................................................................... 481 Leaf Spring Removal And Installation.......................................................................................... 482 Sprocket Removal And Installation (Single Speed).............................................................................. 483 Sprocket Removal And Installation (Two-Speed)................................................................................. 483 Track Housing Removal And Installation........................................................................................ 484 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) (S/N ALJG16001 AND B2KZ12001 & ABOVE).............................................. 485 Description................................................................................................................... 485 Checking (Solid-Mounted Undercarriage)........................................................................................ 487 Adjusting (Solid-Mounted Undercarriage) (Earlier Models With Two Track Tension Fittings)...................................... 488 Adjusting (Solid-Mounted Undercarriage) (Later Models With One Track Tension Fitting)......................................... 489 Track Removal And Installation................................................................................................ 490 Idler (Front) Removal And Installation........................................................................................ 493 Track Tensioner Removal And Installation...................................................................................... 494 Track Tensioner Disassembly And Assembly...................................................................................... 495 Idler (Rear) Removal And Installation......................................................................................... 497 Roller Removal And Installation............................................................................................... 497 Sprocket Removal And Installation (Single Speed).............................................................................. 498 Sprocket Removal And Installation (Two-Speed)................................................................................. 498 Sprocket Removal And Installation (Sixteen Bolt Sprocket)..................................................................... 498 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) (S/N ALJG16001 AND B2KZ12001 & ABOVE).......................................... 499 Description................................................................................................................... 499 Checking (Roller Suspension Undercarriage).................................................................................... 501 Adjusting (Roller Suspension Undercarriage) (Earlier Models With Two Track Tension Fittings).................................. 502 Adjusting (Roller Suspension Undercarriage) (Later Models With One Track Tension Fitting)..................................... 503 Track Removal And Installation................................................................................................ 504 Idler (Front) Removal And Installation........................................................................................ 507 Track Tensioner Removal And Installation...................................................................................... 508 Track Tensioner Disassembly And Assembly...................................................................................... 509 Idler (Rear) Removal And Installation......................................................................................... 511 Roller Removal And Installation............................................................................................... 511 Leaf Spring Removal And Installation.......................................................................................... 512 Sprocket Removal And Installation (Single Speed).............................................................................. 513 Sprocket Removal And Installation (Two-Speed)................................................................................. 513 Sprocket Removal And Installation (Sixteen Bolt Sprocket)..................................................................... 513 TRACK MAINTENANCE................................................................................................................. 515 Track Damage Identification................................................................................................... 515 MAINFRAME............................................................................................................................. 527 SEAT BAR.......................................................................................................................... 531 Description................................................................................................................... 531 Removal And Installation...................................................................................................... 531 Disassembly And Assembly...................................................................................................... 532 Compression Spring Disassembly And Assembly................................................................................... 533 OPERATOR CAB...................................................................................................................... 535 Gas Spring Removal And Installation........................................................................................... 535 Gas Spring Bracket Disassembly And Assembly................................................................................... 536 Removal And Installation...................................................................................................... 537 OPERATOR SEAT..................................................................................................................... 539 Removal And Installation...................................................................................................... 539 Seat Belt Removal And Installation (Retractable).............................................................................. 539 Seat Belt And Bracket Removal And Installation (Standard)..................................................................... 540 Seat Belt Bracket Removal And Installation.................................................................................... 540 OPERATOR SEAT (SUSPENSION)........................................................................................................ 541 Removal And Installation...................................................................................................... 541 Slide Rail Removal And Installation........................................................................................... 541 Seat Belt Removal And Installation............................................................................................ 542 Lower Cushion Removal......................................................................................................... 542 Lower Cushion Installation.................................................................................................... 543 Back Cushion Removal And Installation......................................................................................... 543 Shock Removal And Installation................................................................................................ 544 3-Point Seat Belt Removal And Installation.................................................................................... 544 BOB-TACH (HAND LEVER)............................................................................................................. 547 Description................................................................................................................... 547 Removal And Installation...................................................................................................... 547 Lever And Wedge Disassembly And Assembly...................................................................................... 549 Pivot Pin Bushing And Seal Removal And Installation........................................................................... 552 BOB-TACH (POWER).................................................................................................................. 553 Description................................................................................................................... 553 Removal And Installation...................................................................................................... 553 Lever And Wedge Disassembly And Assembly...................................................................................... 556 Pivot Pin Bushing And Seal Removal And Installation........................................................................... 558 LIFT ARMS......................................................................................................................... 559 Stabilizer Bar Removal And Installation....................................................................................... 559 Link Removal And Installation................................................................................................. 560 Removal And Installation...................................................................................................... 561 REAR GRILLE....................................................................................................................... 565 Removing...................................................................................................................... 565 Installing.................................................................................................................... 566 Shield Removal And Installation............................................................................................... 567 REAR DOOR (TAILGATE).............................................................................................................. 569 Removal And Installation...................................................................................................... 569 Striker Removal And Installation.............................................................................................. 570 Striker Disassembly And Assembly.............................................................................................. 570 Striker (Adjusting)........................................................................................................... 570 Latch Removal And Installation................................................................................................ 571 FUEL TANK......................................................................................................................... 573 Removal And Installation...................................................................................................... 573 Fuel Level Sender Removal And Installation.................................................................................... 575 Fuel Fill Screen Removal And Installation..................................................................................... 575 CONTROL PEDALS AND LINKAGES....................................................................................................... 577 Description................................................................................................................... 577 Pedal Removal And Installation................................................................................................ 577 Linkage Removal And Installation.............................................................................................. 578 Pedal (Adjusting)............................................................................................................. 579 Floor Pan Removal And Installation............................................................................................ 580 CONTROL PEDALS AND LINKAGES (ACS)................................................................................................. 581 Description................................................................................................................... 581 Pedal Removal And Installation................................................................................................ 581 Linkage Removal And Installation.............................................................................................. 582 Pedal (Adjusting)............................................................................................................. 582 Floor Pan Removal And Installation............................................................................................ 583 CONTROL PANEL..................................................................................................................... 585 Description................................................................................................................... 585 Removal And Installation...................................................................................................... 586 Disassembly And Assembly...................................................................................................... 587 Linkage Removal And Installation.............................................................................................. 591 Pintle Arm Disassembly And Assembly........................................................................................... 595 Linkage Neutral (Adjusting)................................................................................................... 596 Linkage Travel (Adjusting).................................................................................................... 600 Shock Removal And Installation................................................................................................ 604 CONTROL PANEL (SJC)............................................................................................................... 605 Description................................................................................................................... 605 Removal And Installation...................................................................................................... 605 CONTROL HANDLE / LEVER............................................................................................................ 607 Description................................................................................................................... 607 Lever Removal And Installation................................................................................................ 607 Boot Removal And Installation................................................................................................. 607 CONTROL HANDLE / LEVER (ACS)...................................................................................................... 609 Description................................................................................................................... 609 Handle Sensor Removal And Installation........................................................................................ 609 Handle Removal And Installation............................................................................................... 612 Handle Disassembly And Assembly............................................................................................... 613 Lever Removal And Installation................................................................................................ 613 Boot Removal And Installation................................................................................................. 614 CONTROL HANDLE / LEVER (SJC)...................................................................................................... 615 Description................................................................................................................... 615 Joystick Testing.............................................................................................................. 615 Joystick Removal And Installation............................................................................................. 616 ACCESS PANEL (INSIDE)............................................................................................................. 617 Removal And Installation (Left)............................................................................................... 617 Removal And Installation (Right).............................................................................................. 617 ACCESS PANEL (INSIDE) (SJC)....................................................................................................... 619 Removal And Installation (Left)............................................................................................... 619 Removal And Installation (Right).............................................................................................. 619 WINDOW (REAR)..................................................................................................................... 621 Rear Window Identification.................................................................................................... 621 Removal And Installation (Latches)............................................................................................ 621 Disassembly And Assembly (Latches)............................................................................................ 622 Removal (Rubber Cord)......................................................................................................... 623 Installation (Rubber Cord).................................................................................................... 624 WINDOW (TOP)...................................................................................................................... 627 Removal And Installation...................................................................................................... 627 WINDOW (SIDE)..................................................................................................................... 629 Removal And Installation...................................................................................................... 629 CAB DOOR.......................................................................................................................... 631 Description................................................................................................................... 631 Removal And Installation...................................................................................................... 631 Disassembly And Assembly...................................................................................................... 632 Aligning...................................................................................................................... 633 Adjusting..................................................................................................................... 634 Checking Operation............................................................................................................ 634 ARMREST........................................................................................................................... 635 Description................................................................................................................... 635 Removal And Installation...................................................................................................... 636 Disassembly And Assembly...................................................................................................... 637 LEFT SIDE LOWER PANEL............................................................................................................. 641 Removal And Installation...................................................................................................... 641 Disassembly And Assembly...................................................................................................... 643 RIGHT SIDE LOWER PANEL............................................................................................................ 645 Removal And Installation...................................................................................................... 645 Disassembly And Assembly...................................................................................................... 646 HEADLINER......................................................................................................................... 649 Removal And Installation...................................................................................................... 649 FAN DUCT PANELS................................................................................................................... 651 Removal And Installation...................................................................................................... 651 ELECTRICAL SYSTEM..................................................................................................................... 653 ELECTRICAL SCHEMATICS............................................................................................................. 659 ELECTRICAL SYSTEM INFORMATION..................................................................................................... 831 Glossary Of Electrical Symbols................................................................................................ 831 Standard Cab Harness Connectors............................................................................................... 834 Deluxe Cab Harness Connectors................................................................................................. 835 Mainframe Harness Connectors - Manual Controls................................................................................ 836 Mainframe Harness Connectors - SJC............................................................................................ 837 Engine Harness Connectors..................................................................................................... 838 Description................................................................................................................... 839 Troubleshooting............................................................................................................... 840 Fuse And Relay Location / Identification...................................................................................... 841 Solenoid Testing.............................................................................................................. 846 BATTERY........................................................................................................................... 847 Removal And Installation...................................................................................................... 847 Servicing..................................................................................................................... 848 Maintaining Battery Charge Level.............................................................................................. 848 Battery Service During Machine Storage........................................................................................ 848 Battery Testing............................................................................................................... 849 Battery Charging.............................................................................................................. 849 Using A Booster Battery (Jump Starting)....................................................................................... 850 ALTERNATOR........................................................................................................................ 851 Belt Adjustment............................................................................................................... 851 Belt Replacement.............................................................................................................. 851 Charging System Inspection.................................................................................................... 852 Alternator Voltage Testing.................................................................................................... 853 Low Voltage Testing........................................................................................................... 853 High Voltage Testing.......................................................................................................... 854 Removal And Installation...................................................................................................... 855 Parts Identification.......................................................................................................... 857 STARTER........................................................................................................................... 859 Testing....................................................................................................................... 859 Removal And Installation...................................................................................................... 859 Parts Identification.......................................................................................................... 860 INSTRUMENT PANEL IDENTIFICATION................................................................................................... 861 Left Panel.................................................................................................................... 861 Display Screen................................................................................................................ 863 Right Panel (Standard Key Panel).............................................................................................. 864 Right Panel (Keyless Start Panel)............................................................................................. 865 Right Panel (Deluxe Instrumentation Panel).................................................................................... 866 Left Switch Panel............................................................................................................. 868 Right Switch Panel............................................................................................................ 868 Left Side Lower Panel......................................................................................................... 869 Right Side Lower Panel........................................................................................................ 869 Left Panel Removal And Installation........................................................................................... 870 Right Panel (Standard Key Panel) Removal And Installation..................................................................... 870 Right Panel (Keyless Start Panel) Removal And Installation.................................................................... 871 Right Panel (Deluxe Instrumentation Panel) Removal And Installation........................................................... 871 Key Switch Disassembly And Assembly........................................................................................... 872 Alarm Disassembly And Assembly................................................................................................ 872 Left Switch Panel Removal And Installation.................................................................................... 872 Right Switch Panel Removal And Installation................................................................................... 873 LIGHTS............................................................................................................................ 875 Front Removal And Installation................................................................................................ 875 Rear Removal And Installation................................................................................................. 876 Cab Light Removal And Installation (Earlier Models)........................................................................... 876 Cab Light Removal And Installation (Later Models)............................................................................. 877 BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)........................................................................................ 879 Description................................................................................................................... 879 Connector Identification...................................................................................................... 880 Removal And Installation...................................................................................................... 886 BOBCAT CONTROLLER (ACS)........................................................................................................... 887 Description................................................................................................................... 887 Connector And Wire Identification............................................................................................. 888 Removal And Installation...................................................................................................... 889 BOBCAT CONTROLLER (SJC) (DRIVE)................................................................................................... 891 Description................................................................................................................... 891 Connector Identification...................................................................................................... 892 Removal And Installation...................................................................................................... 894 ENGINE CONTROL UNIT (ECU)......................................................................................................... 895 Description................................................................................................................... 895 Cleaning...................................................................................................................... 896 Removal And Installation...................................................................................................... 897 DIAGNOSTIC SERVICE CODES.......................................................................................................... 899 Viewing Service Codes......................................................................................................... 899 Service Codes List............................................................................................................ 900 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)........................................................................................... 909 Description................................................................................................................... 909 Inspecting The BICS™ (Engine STOPPED - Key ON)................................................................................ 910 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON).......................................... 910 Inspecting The Seat Bar Sensor (Engine RUNNING)............................................................................... 910 Inspecting The Traction Lock And Parking Brake (Engine RUNNING)............................................................... 910 Inspecting The Lift Arm Bypass Control........................................................................................ 910 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC).............................................................. 910 Troubleshooting............................................................................................................... 911 SEAT BAR SENSOR................................................................................................................... 913 Description................................................................................................................... 913 Troubleshooting............................................................................................................... 913 Testing....................................................................................................................... 914 Removal And Installation...................................................................................................... 915 Bobcat Interlock Control System (BICS™) Circuit Test.......................................................................... 918 TRACTION LOCK..................................................................................................................... 921 Description................................................................................................................... 921 Troubleshooting............................................................................................................... 922 Inspecting.................................................................................................................... 923 CONTROL SYSTEM (ACS).............................................................................................................. 925 Description................................................................................................................... 925 Troubleshooting............................................................................................................... 926 Handle Sensor Connector Disassembly And Assembly.............................................................................. 927 Switch Handle Removal......................................................................................................... 928 Switch Handle Installation.................................................................................................... 930 Actuator Connector Disassembly And Assembly................................................................................... 933 Handle Lock Solenoid Removal And Installation................................................................................. 934 Handle Lock Solenoid Disassembly And Assembly................................................................................. 934 Foot Sensor Removal And Installation.......................................................................................... 935 Foot Sensor Disassembly And Assembly.......................................................................................... 936 Foot Sensor Lock Solenoid Removal And Installation............................................................................ 936 ELECTRICAL / HYDRAULIC CONTROLS................................................................................................... 937 Identification Chart.......................................................................................................... 937 Description................................................................................................................... 938 Identification Chart ACD Group 0.............................................................................................. 939 Identification Chart ACD Group 1.............................................................................................. 940 Identification Chart ACD Group 2.............................................................................................. 941 Identification Chart ACD Group 3.............................................................................................. 942 ELECTRICAL / HYDRAULIC CONTROLS (ACS)............................................................................................. 943 Identification Chart.......................................................................................................... 943 Description................................................................................................................... 944 Identification Chart ACD Group 0.............................................................................................. 945 Identification Chart ACD Group 1.............................................................................................. 946 Identification Chart ACD Group 2.............................................................................................. 947 Identification Chart ACD Group 3.............................................................................................. 948 ELECTRICAL / HYDRAULIC CONTROLS (SJC)............................................................................................. 949 Identification Chart.......................................................................................................... 949 Description................................................................................................................... 950 Identification Chart ACD Group 0.............................................................................................. 951 Identification Chart ACD Group 1.............................................................................................. 952 Identification Chart ACD Group 2.............................................................................................. 953 Identification Chart ACD Group 3.............................................................................................. 954 SERVICE PC (LAPTOP COMPUTER)...................................................................................................... 955 Connecting Remote Start Tool.................................................................................................. 955 Connecting Remote Start Tool (Service Tool)................................................................................... 955 CALIBRATION....................................................................................................................... 957 Description................................................................................................................... 957 Actuator Testing.............................................................................................................. 957 Lift And Tilt Calibration (SJC)............................................................................................... 960 Hydrostatic Pump Calibration (SJC)............................................................................................ 962 Lift And Tilt Calibration (ACS)............................................................................................... 967 STEERING DRIFT COMPENSATION (OPERATOR MODE)....................................................................................... 969 Description................................................................................................................... 969 Operation..................................................................................................................... 969 STEERING DRIFT COMPENSATION (SERVICE MODE)........................................................................................ 971 Description................................................................................................................... 971 Operation..................................................................................................................... 971 CONTROL PANEL SETUP............................................................................................................... 973 Right Panel Setup (Deluxe Instrumentation Panel).............................................................................. 973 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)..................................................................................... 977 Password Description.......................................................................................................... 977 Changing The Owner Password................................................................................................... 977 Changing The User Passwords................................................................................................... 978 Password Lockout Feature...................................................................................................... 978 PASSWORD SETUP (KEYLESS START PANEL).............................................................................................. 979 Password Description.......................................................................................................... 979 Changing The Owner Password................................................................................................... 979 Password Lockout Feature...................................................................................................... 979 MAINTENANCE CLOCK................................................................................................................. 981 Description................................................................................................................... 981 Setup......................................................................................................................... 982 Reset......................................................................................................................... 985 BACK-UP ALARM SYSTEM.............................................................................................................. 987 Description................................................................................................................... 987 Inspecting.................................................................................................................... 987 Adjusting Switch Position..................................................................................................... 988 Troubleshooting (Standard And ACS)............................................................................................ 989 Troubleshooting (Joystick).................................................................................................... 990 Alarm Removal And Installation................................................................................................ 991 Switch Removal And Installation............................................................................................... 991 FRONT HORN........................................................................................................................ 993 Removal And Installation...................................................................................................... 993 Troubleshooting............................................................................................................... 994 Troubleshooting (Joystick).................................................................................................... 995 ENGINE SPEED CONTROL (HAND)....................................................................................................... 997 Removal And Installation...................................................................................................... 997 ENGINE SPEED CONTROL (FOOT)....................................................................................................... 999 Removal And Installation...................................................................................................... 999 Disassembly And Assembly......................................................................................................1000 Foot Throttle Calibration.....................................................................................................1002 CAMSHAFT AND CRANKSHAFT POSITION SENSOR...........................................................................................1005 Removal And Installation......................................................................................................1005 TELEMATICS........................................................................................................................1007 Description...................................................................................................................1007 Removal And Installation......................................................................................................1007 Procedure.....................................................................................................................1008 ENGINE SERVICE........................................................................................................................1009 ENGINE INFORMATION................................................................................................................1013 Description...................................................................................................................1013 Specifications................................................................................................................1014 Sensor Location...............................................................................................................1016 Torque Values.................................................................................................................1022 Troubleshooting...............................................................................................................1024 Engine Removal And Installation...............................................................................................1026 Engine Mount Replacement......................................................................................................1035 Compression - Testing.........................................................................................................1037 Injector Signal - Testing.....................................................................................................1039 Injector Signal - Testing (In-Line)...........................................................................................1041 Oil Pressure Testing (At Oil Sensor On Block).................................................................................1043 Oil Pressure Testing (At Turbocharger Oil Inlet)..............................................................................1045 DIESEL OXIDATION CATALYST (DOC)...................................................................................................1047 Removal And Installation......................................................................................................1047 AIR CLEANER.......................................................................................................................1049 Housing Removal And Installation..............................................................................................1049 ENGINE COOLING SYSTEM (EARLIER MODELS)............................................................................................1051 Radiator / Oil Cooler Removal And Installation................................................................................1051 Hydraulic Fan Description.....................................................................................................1054 Fan Duct Removal And Installation.............................................................................................1054 Hydraulic Fan Motor Assembly Removal And Installation.........................................................................1055 Hydraulic Fan Motor Removal And Installation..................................................................................1056 Hydraulic Fan Motor Disassembly And Assembly..................................................................................1058 Blower Housing Removal And Installation.......................................................................................1059 Water Pump Removal And Installation...........................................................................................1060 Thermostat Housing Removal And Installation...................................................................................1061 Testing The Thermostat........................................................................................................1062 ENGINE COOLING SYSTEM (LATER MODELS)..............................................................................................1063 Radiator / Oil Cooler Removal And Installation................................................................................1063 Hydraulic Fan Description.....................................................................................................1066 Reversible Hydraulic Fan Description..........................................................................................1066 Fan Duct Removal And Installation.............................................................................................1066 Hydraulic Fan Motor Assembly Removal And Installation.........................................................................1067 Hydraulic Fan Motor Removal And Installation..................................................................................1068 Hydraulic Fan Motor Disassembly And Assembly..................................................................................1070 Blower Housing Removal And Installation.......................................................................................1078 Water Pump Removal And Installation...........................................................................................1079 Thermostat Housing Removal And Installation...................................................................................1080 Testing The Thermostat........................................................................................................1081 LUBRICATION SYSTEM................................................................................................................1083 Description...................................................................................................................1083 Oil Pan Removal And Installation..............................................................................................1084 Oil Pump Removal And Installation.............................................................................................1085 Oil Pump Relief Valve Description.............................................................................................1086 Oil Pump Relief Valve Removal And Installation................................................................................1086 Oil Cooler Removal And Installation...........................................................................................1086 Oil Filter Head Removal And Installation......................................................................................1087 Oil Cooler Bypass Description.................................................................................................1087 Oil Cooler Bypass Removal And Installation....................................................................................1087 FUEL SYSTEM.......................................................................................................................1089 Description...................................................................................................................1089 Transfer Pump / High Pressure Pump Removal And Installation...................................................................1090 Fuel Temperature Sensor Removal And Installation..............................................................................1092 Fuel Cooler Removal And Installation..........................................................................................1093 Fuel Bypass Valve Removal And Installation....................................................................................1093 Fuel Recirculation Valve Removal And Installation.............................................................................1094 Fuel Rail Assembly Removal And Installation...................................................................................1095 Fuel Injector Removal And Installation........................................................................................1096 Injector Coding...............................................................................................................1098 Removing Air From The Fuel System.............................................................................................1100 CYLINDER HEAD.....................................................................................................................1103 Glow Plugs Testing............................................................................................................1103 Glow Plug Removal And Installation............................................................................................1104 Valve Clearance Adjustment....................................................................................................1105 Cylinder Head Removal And Installation........................................................................................1107 Cylinder Head Disassembly And Assembly........................................................................................1111 Cylinder Head Inspection......................................................................................................1112 Cylinder Head Top Clearance...................................................................................................1113 Valve Step Height.............................................................................................................1114 Valve Stem Height.............................................................................................................1114 Valve Guide...................................................................................................................1115 Valve.........................................................................................................................1115 Valve Spring..................................................................................................................1116 Rocker Arm Shaft Disassembly And Assembly.....................................................................................1117 Rocker Arm Shaft Inspection...................................................................................................1118 Push Rod Inspection...........................................................................................................1118 CRANKSHAFT AND PISTONS............................................................................................................1119 Piston And Connecting Rod Removal And Installation............................................................................1119 Piston And Connecting Rod Inspection..........................................................................................1120 Crankshaft Removal And Installation...........................................................................................1122 Cylinder Block Inspection.....................................................................................................1125 Crankshaft Inspection.........................................................................................................1127 Connecting Rod Inspection.....................................................................................................1127 Engine Component Class........................................................................................................1128 CAMSHAFT..........................................................................................................................1131 Removal And Installation......................................................................................................1131 Inspecting....................................................................................................................1132 GEARCASE..........................................................................................................................1135 Gearcase Cover Removal And Installation.......................................................................................1135 Gear Backlash.................................................................................................................1136 Gear Timing...................................................................................................................1137 Idle Gear Removal And Installation............................................................................................1138 Idle Gear Inspection..........................................................................................................1138 TURBOCHARGER......................................................................................................................1139 Description...................................................................................................................1139 Removal And Installation......................................................................................................1139 Inspection....................................................................................................................1142 FLYWHEEL AND HOUSING..............................................................................................................1143 Flywheel Removal And Installation.............................................................................................1143 Ring Gear Removal And Installation............................................................................................1144 Housing Removal And Installation..............................................................................................1144 EXHAUST GAS RECIRCULATION (EGR) SYSTEM............................................................................................1145 Description...................................................................................................................1145 Removal And Installation......................................................................................................1146 Disassembly And Assembly......................................................................................................1150 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)......................................................................................1153 AIR CONDITIONING SYSTEM FLOW......................................................................................................1155 Description...................................................................................................................1155 Chart.........................................................................................................................1156 Components....................................................................................................................1157 Safety Equipment..............................................................................................................1160 REGULAR MAINTENANCE...............................................................................................................1161 Filters.......................................................................................................................1161 Belt Adjustment...............................................................................................................1162 Belt Replacement..............................................................................................................1162 Condenser.....................................................................................................................1162 Air Conditioning Lubrication..................................................................................................1162 Air Conditioning Service Chart................................................................................................1163 Evaporator / Heater Coil......................................................................................................1164 TROUBLESHOOTING...................................................................................................................1167 Blower Motor Does Not Operate.................................................................................................1167 Blower Motor Operates Normally, But Air Flow Is Insufficient..................................................................1167 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....................................................1167 The Compressor Does Not Operate At All, Or Operates Improperly................................................................1167 Gauge Pressure Related Troubleshooting........................................................................................1168 Troubleshooting Tree..........................................................................................................1170 Temperature / Pressure Chart..................................................................................................1174 Poor A/C Performance..........................................................................................................1176 HVAC Repair And Leaks.........................................................................................................1177 Electrical System.............................................................................................................1178 Engine Coolant Bypassing The Heater Valve.....................................................................................1184 Heater Valve Not Opening Or Closing...........................................................................................1185 SYSTEM CHARGING AND RECLAMATION...................................................................................................1187 Refrigerant Identification....................................................................................................1187 Reclamation And Charging With Recovery / Charging Unit........................................................................1188 COMPRESSOR........................................................................................................................1191 Removal And Installation......................................................................................................1191 Oil...........................................................................................................................1192 Oil Check.....................................................................................................................1193 CONDENSER.........................................................................................................................1195 Removal And Installation......................................................................................................1195 RECEIVER / DRIER..................................................................................................................1197 Receiver / Drier Removal And Installation.....................................................................................1197 Pressure Switch Removal And Installation......................................................................................1198 Schrader® Valve Removal And Installation......................................................................................1199 EVAPORATOR / HEATER UNIT..........................................................................................................1201 Removal And Installation......................................................................................................1201 THERMOSTAT........................................................................................................................1203 Description...................................................................................................................1203 Removal And Installation......................................................................................................1204 EXPANSION VALVE...................................................................................................................1205 Removal And Installation......................................................................................................1205 EVAPORATOR COIL...................................................................................................................1207 Removal And Installation......................................................................................................1207 HEATER COIL.......................................................................................................................1209 Removal And Installation......................................................................................................1209 BLOWER FAN........................................................................................................................1211 Removal And Installation......................................................................................................1211 Disassembly And Assembly......................................................................................................1212 HEATER VALVE......................................................................................................................1215 Removal And Installation......................................................................................................1215 EVAPORATOR / HEATER COVER.........................................................................................................1217 Removing......................................................................................................................1217 Installing....................................................................................................................1217 SPECIFICATIONS........................................................................................................................1219 (T650) LOADER SPECIFICATIONS (S/N ALJG11001 - ALJG14489 AND T1ML11001 & ABOVE)....................................................1223 Machine Dimensions............................................................................................................1223 Performance...................................................................................................................1224 Engine........................................................................................................................1224 Drive System..................................................................................................................1225 Controls......................................................................................................................1225 Hydraulic System..............................................................................................................1226 Electrical System.............................................................................................................1227 Capacities....................................................................................................................1227 Tracks........................................................................................................................1228 Ground Pressure...............................................................................................................1228 (T650) LOADER SPECIFICATIONS (S/N ALJG14490 & ABOVE)..............................................................................1229 Machine Dimensions............................................................................................................1229 Performance...................................................................................................................1230 Engine........................................................................................................................1230 Drive System..................................................................................................................1231 Controls......................................................................................................................1231 Hydraulic System..............................................................................................................1232 Electrical System.............................................................................................................1233 Capacities....................................................................................................................1233 Tracks........................................................................................................................1234 Ground Pressure...............................................................................................................1234 (T650) LOADER SPECIFICATIONS (S/N B2KZ11001 - B2KZ11999)..........................................................................1235 Machine Dimensions............................................................................................................1235 Performance...................................................................................................................1236 Engine........................................................................................................................1236 Drive System..................................................................................................................1237 Controls......................................................................................................................1237 Hydraulic System..............................................................................................................1238 Electrical System.............................................................................................................1239 Capacities....................................................................................................................1239 Tracks........................................................................................................................1240 Ground Pressure...............................................................................................................1240 (T650) LOADER SPECIFICATIONS (S/N B2KZ12001 & ABOVE)..............................................................................1241 Machine Dimensions............................................................................................................1241 Performance...................................................................................................................1242 Engine........................................................................................................................1242 Drive System..................................................................................................................1243 Controls......................................................................................................................1243 Hydraulic System..............................................................................................................1244 Electrical System.............................................................................................................1245 Capacities....................................................................................................................1245 Tracks........................................................................................................................1246 Ground Pressure...............................................................................................................1246 (T650) LOADER SPECIFICATIONS FOR MACHINES WITH SIX OR EIGHT TRACK SPROCKET NUT (S/N ALJG12077 & ABOVE)............................1247 Machine Dimensions............................................................................................................1247 Performance...................................................................................................................1248 Engine........................................................................................................................1248 Drive System..................................................................................................................1249 Controls......................................................................................................................1249 Hydraulic System..............................................................................................................1250 Electrical System.............................................................................................................1251 Capacities....................................................................................................................1251 Tracks........................................................................................................................1252 Ground Pressure...............................................................................................................1252 (T650) LOADER SPECIFICATIONS FOR MACHINES WITH SIXTEEN TRACK SPROCKET BOLTS (S/N ALJG12007 & ABOVE)...............................1253 Machine Dimensions............................................................................................................1253 Performance...................................................................................................................1254 Engine........................................................................................................................1254 Drive System..................................................................................................................1255 Controls......................................................................................................................1255 Hydraulic System..............................................................................................................1256 Electrical System.............................................................................................................1257 Capacities....................................................................................................................1257 Tracks........................................................................................................................1258 Ground Pressure...............................................................................................................1258 TECHINCAL SERVICE GUIDE SPECIFICATIONS............................................................................................1259 Engine........................................................................................................................1259 Engine Torques................................................................................................................1259 Cooling System................................................................................................................1259 Loader Torques................................................................................................................1260 Hydraulic / Hydrostatic System................................................................................................1260 Fuel Consumption..............................................................................................................1260 TORQUE SPECIFICATIONS FOR BOLTS...................................................................................................1261 Torque For General SAE Bolts..................................................................................................1261 Torque For General Metric Bolts...............................................................................................1262 HYDRAULIC CONNECTION SPECIFICATIONS...............................................................................................1263 Straight Thread O-ring Fitting................................................................................................1263 Flare Fitting.................................................................................................................1264 Tubelines And Hoses...........................................................................................................1264 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS......................................................................................1265 Specifications................................................................................................................1265 CONVERSIONS.......................................................................................................................1267 Decimal And Millimeter Equivalent Chart.......................................................................................1267 U.S. To Metric Conversion Chart...............................................................................................1267 SERVICE TOOLS REQUIRED............................................................................................................1269 Remote Start Tools............................................................................................................1269 Hydraulic Tools...............................................................................................................1270 Mainframe And Drive Tools.....................................................................................................1273 Electrical Tools..............................................................................................................1276 Engine Tools..................................................................................................................1277 HVAC Tools....................................................................................................................1282 ALPHABETICAL INDEX....................................................................................................................1283
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