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Bobcat T66 Compact Track Loader Service Manual SN B4SB11001 & Above – PDF DOWNLOAD
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Bobcat T66 Compact Track Loader Service Manual SN B4SB11001 & Above – PDF DOWNLOAD
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Description
Bobcat T66 Compact Track Loader Service Manual SN B4SB11001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat T66 Compact Track Loader Service Manual SN B4SB11001 & Above – PDF DOWNLOAD
Language : English
Pages : 930
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T66 Compact Track Loader Service Manual SN B4SB11001 & Above – PDF DOWNLOAD
FOREWORD:
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS / FOPS (Including side screens) is in good condition and is not modified.
2. Check that ROPS mounting hardware is tightened and is Bobcat approved.
3. The seat belt must be correctly installed, functional and in good condition.
4. The seat bar must be correctly adjusted, clean and lubricated.
5. Check lift arm support device, replace if damaged.
6. Machine signs (decals) must be legible and in the correct location.
7. Steering levers, hand controls and foot pedals must return to neutral (as applicable).
8. Check for correct function of the work lights.
9. The parking brake must function correctly.
10. Enclosure door latches must open and close freely.
11. Bob-Tach® attachment mounting system wedges and linkages must function correctly and be in good condition.
12. Safety treads must be in good condition.
13. Check for correct function of indicator lamps.
14. Check all machine fluid levels.
15. Inspect for fuel, oil or hydraulic fluid leaks.
SAFETY INSTRUCTIONS:
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
• The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
• The AEM Safety Manual delivered with the machine gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Bobcat T66 Compact Track Loader Service Manual SN B4SB11001 & Above – PDF DOWNLOAD
MAINTENANCE SAFETY....................................................................... 3 CONTENTS................................................................................. 5 FOREWORD................................................................................. 7 FOREWORD............................................................................. 9 SAFETY INSTRUCTIONS.................................................................. 11 FIRE PREVENTION...................................................................... 13 Maintenance...................................................................... 13 Operation........................................................................ 13 Electrical....................................................................... 13 Hydraulic System................................................................. 13 Fueling.......................................................................... 13 Starting......................................................................... 13 Spark Arrester Exhaust System.................................................... 13 Welding And Grinding............................................................. 14 Fire Extinguishers............................................................... 14 SERIAL NUMBER LOCATIONS.............................................................. 15 Machine Serial Number Location................................................... 15 Engine Serial Number Location.................................................... 15 DELIVERY REPORT...................................................................... 16 LOADER IDENTIFICATION................................................................ 17 SAFETY & MAINTENANCE..................................................................... 19 LIFTING AND BLOCKING THE LOADER...................................................... 23 Procedure........................................................................ 23 LIFT ARM SUPPORT DEVICE.............................................................. 25 Lift Arm Support Device Description.............................................. 25 Installing Lift Arm Support Device............................................... 25 Removing Lift Arm Support Device................................................. 27 OPERATOR CAB......................................................................... 29 Inspecting Operator Cab.......................................................... 29 Cab Door Sensor Description...................................................... 29 Raising Operator Cab............................................................. 30 Lowering Operator Cab............................................................ 31 Special Applications Kit......................................................... 33 Inspecting And Maintaining Special Applications Kit.............................. 33 Forestry Door And Window Kit..................................................... 34 Inspecting And Maintaining Forestry Door And Window Kit.......................... 34 TRANSPORTING THE LOADER ON A TRAILER................................................. 35 Loading And Unloading Machine.................................................... 35 Fastening Machine To Transport Vehicle........................................... 36 TOWING THE LOADER.................................................................... 37 Procedure........................................................................ 37 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....................................... 39 Description...................................................................... 39 Remote Start Tool (Service Tool) - 7022042....................................... 40 Loader Service Tool Harness - 6689747............................................ 41 Computer Service Tool Harness - 6689746.......................................... 42 Remote Start Procedure........................................................... 43 SERVICE SCHEDULE..................................................................... 47 Maintenance Intervals............................................................ 47 ENGINE AIR CLEANER................................................................... 51 Replacing Engine Air Filter Element (Outer)...................................... 51 Replacing Engine Air Filter Element (Inner)...................................... 52 ENGINE COOLING SYSTEM................................................................ 53 Cleaning Engine Cooling System................................................... 53 Checking And Adding Coolant...................................................... 55 Replacing Coolant................................................................ 56 FUEL SYSTEM.......................................................................... 59 Fuel Specifications.............................................................. 59 Biodiesel Blend Fuel............................................................. 59 Filling The Fuel Tank............................................................ 60 Removing Water From Main Fuel Filter............................................. 61 Replacing Fuel Pre-Filter........................................................ 62 Replacing Main Fuel Filter....................................................... 63 Replacing Fuel Tank Vent Filter.................................................. 65 ENGINE LUBRICATION SYSTEM............................................................ 67 Checking And Adding Engine Oil................................................... 67 Engine Oil Chart................................................................. 67 Replacing Engine Oil And Filter.................................................. 68 HYDRAULIC SYSTEM..................................................................... 71 Checking And Adding Hydraulic Fluid.............................................. 71 Hydraulic Fluid Chart............................................................ 72 Replacing Hydraulic Fluid........................................................ 73 Replacing Main Hydraulic Filter.................................................. 77 Replacing Hydraulic Case Drain Filter............................................ 79 Replacing Hydraulic Charge Filter................................................ 80 Replacing Hydraulic Reservoir Vent Filter........................................ 82 BOB-TACH (HAND LEVER)................................................................ 83 Inspecting And Maintaining Hand Lever Bob-Tach................................... 83 BOB-TACH (POWER)..................................................................... 85 Inspecting And Maintaining Power Bob-Tach........................................ 85 LUBRICATING THE LOADER............................................................... 87 Lubricating Grease Fittings...................................................... 87 PIVOT PINS........................................................................... 89 Checking Pivot Pin Torque........................................................ 89 LOADER STORAGE AND RETURN TO SERVICE................................................. 91 Loader Extended Storage Procedure................................................ 91 Loader Return To Service Procedure............................................... 91 STOPPING THE ENGINE AND LEAVING THE MACHINE.......................................... 93 Procedure........................................................................ 93 EMERGENCY EXITS...................................................................... 95 Removing Rear Window With Latches................................................ 95 Removing Rear Window With Rubber Cord............................................ 95 Removing Rear Window With Latches From Outside Loader............................ 96 Removing Rear Window With Rubber Cord From Outside Loader........................ 97 Removing Front Door.............................................................. 97 Front Door Reassembly............................................................ 98 SEAT BELT............................................................................ 99 Inspection And Maintenance....................................................... 99 HYDRAULIC SYSTEM.........................................................................101 HYDRAULIC / HYDROSTATIC SCHEMATICS...................................................105 HYDRAULIC SYSTEM INFORMATION.........................................................113 Glossary Of Hydraulic Symbols....................................................113 Troubleshooting..................................................................117 CYLINDER (LIFT)......................................................................119 Testing..........................................................................119 Removal And Installation.........................................................120 Parts Identification.............................................................124 Disassembly......................................................................125 Assembly.........................................................................128 CYLINDER (TILT)......................................................................133 Testing..........................................................................133 Removal And Installation.........................................................134 Base End Pivot Pin Removal And Installation......................................136 Parts Identification.............................................................137 Disassembly......................................................................138 Assembly.........................................................................141 CYLINDER (BOB-TACH)..................................................................145 Testing..........................................................................145 Removal And Installation.........................................................146 Parts Identification.............................................................147 Disassembly......................................................................148 Assembly.........................................................................149 MAIN RELIEF VALVE....................................................................153 Description......................................................................153 Testing..........................................................................154 Main Relief Valve Adjustment.....................................................155 Main Relief Valve Removal And Installation.......................................156 HYDRAULIC CONTROL VALVE..............................................................157 Description......................................................................157 Removal And Installation.........................................................157 Actuator Removal And Installation................................................162 Identification Chart.............................................................165 Lift Load Check Valve Removal And Installation...................................166 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)...................168 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....168 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....169 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).....169 Port Relief Valve Removal And Installation.......................................170 Plug Removal And Installation....................................................172 End Cap Block Removal And Installation...........................................173 Lift Spool Removal And Installation..............................................173 Lift Spool Disassembly And Assembly..............................................175 Tilt Spool Removal And Installation..............................................176 Tilt Spool Disassembly And Assembly..............................................177 Auxiliary Spool Removal And Installation.........................................178 Auxiliary Solenoid Removal And Installation......................................179 Solenoid Removal And Installation................................................180 Lock Valve Removal And Installation..............................................181 Lift Arm Bypass Orifice Removal And Installation.................................183 Main Relief Valve Removal And Installation.......................................183 Check Valve Removal And Installation.............................................184 LIFT ARM BYPASS CONTROL VALVE........................................................185 Description......................................................................185 Testing..........................................................................185 Removal And Installation.........................................................186 Bracket Removal And Installation.................................................187 Disassembly And Assembly.........................................................187 HYDRAULIC PUMP.......................................................................189 Description......................................................................189 Pump Test At Quick Couplers......................................................190 Direct Pump Test (Standard Section)..............................................191 Direct Pump Test (Charge Section)................................................193 Removal And Installation.........................................................195 Hydraulic Pump Startup...........................................................198 Parts Identification.............................................................199 Disassembly And Assembly.........................................................200 HYDRAULIC PUMP (HIGH FLOW)...........................................................201 Description......................................................................201 Pump Test At Quick Couplers......................................................202 Direct Pump Test (Standard Section)..............................................203 Direct Pump Test (Charge Section)................................................204 Direct Pump Test (High Flow Section).............................................206 High Flow Relief Valve Adjustment................................................208 High Flow Relief Valve Removal And Installation..................................209 Solenoid Removal And Installation................................................210 Removal And Installation.........................................................211 Hydraulic Pump Startup...........................................................214 Parts Identification.............................................................215 Disassembly And Assembly.........................................................216 HYDRAULIC FILTERS....................................................................217 Description......................................................................217 Housing Removal And Installation.................................................217 HYDRAULIC FLUID RESERVOIR............................................................219 Description......................................................................219 Removal And Installation.........................................................220 OIL COOLER...........................................................................223 Description......................................................................223 Removal And Installation.........................................................223 BUCKET POSITION SENSORS..............................................................225 Description......................................................................225 Removal And Installation.........................................................225 REAR AUXILIARY DIVERTER VALVE........................................................227 Description......................................................................227 Removal And Installation.........................................................227 Disassembly And Assembly.........................................................230 Bob-Tach (POWER) BLOCK...............................................................235 Description......................................................................235 Testing Relief Valve.............................................................236 Removal And Installation.........................................................238 Disassembly And Assembly.........................................................240 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK..............................................245 Description......................................................................245 Removal And Installation.........................................................246 Disassembly And Assembly.........................................................247 AUTOMATIC RIDE CONTROL...............................................................249 Description......................................................................249 Removal And Installation.........................................................250 Checking The Pressure In The Accumulator.........................................252 Adding Nitrogen To The Accumulator...............................................254 HYDROSTATIC SYSTEM.......................................................................257 HYDROSTATIC SYSTEM INFORMATION.......................................................259 Description......................................................................259 Troubleshooting..................................................................259 HYDROSTATIC DRIVE MOTOR..............................................................261 Description......................................................................261 Removing And Replacing Fluid.....................................................261 Removal And Installation.........................................................262 Parts Identification (MCR5T) (One-Speed).........................................265 Parts Identification (MCR6T) (Two-Speed).........................................266 Disassembly And Assembly.........................................................267 CHARGE PRESSURE......................................................................277 Description......................................................................277 Testing..........................................................................277 Sender Removal And Installation..................................................279 Adjusting........................................................................280 HYDROSTATIC PUMP (MANUAL)............................................................281 Description......................................................................281 Port Locations And Gauge Installation............................................282 Removal And Installation.........................................................283 Hydrostatic Pump Startup.........................................................285 Disassembly And Assembly.........................................................286 HYDROSTATIC PUMP (SJC)...............................................................295 Description......................................................................295 Port Locations And Gauge Installation............................................296 Removal And Installation.........................................................297 Hydrostatic Pump Startup.........................................................300 Parts Identification.............................................................301 High Pressure Relief And Bypass Valve............................................304 Charge Pressure Relief Valve.....................................................305 Disassembly And Assembly.........................................................306 Mechanical Neutral Adjustment....................................................318 Hydraulic Controller Neutral Adjustment..........................................320 TWO-SPEED / BRAKE VALVE..............................................................323 Description......................................................................323 Valve Block Removal And Installation.............................................324 Valve Block Disassembly And Assembly.............................................326 DRAIN MANIFOLD.......................................................................329 Description......................................................................329 Drain Manifold Housing Removal And Installation..................................329 DRIVE SYSTEM.............................................................................331 BRAKE................................................................................333 Description......................................................................333 Block Removal And Installation...................................................333 Block Disassembly And Assembly...................................................335 BRAKE (TWO-SPEED)....................................................................337 Description......................................................................337 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED).......................................339 Description......................................................................339 Checking Tension.................................................................340 Adjusting Tension................................................................341 Track Removal And Installation...................................................343 Idler (Front) Removal And Installation...........................................346 Track Tensioner Removal And Installation.........................................347 Track Tensioner Disassembly And Assembly.........................................348 Idler (Rear) Removal And Installation............................................350 Roller Removal And Installation..................................................350 Sprocket Removal And Installation................................................351 Track Frame Removal And Installation.............................................352 TRACK UNDERCARRIAGE COMPONENTS (TORSION SUSPENSION)..................................353 Description......................................................................353 Checking Tension.................................................................355 Adjusting Tension................................................................356 Track Removal And Installation...................................................358 Idler (Front) Removal And Installation...........................................361 Track Tensioner Removal And Installation.........................................362 Track Tensioner Disassembly And Assembly.........................................363 Idler (Rear) Removal And Installation............................................365 Roller Removal And Installation..................................................365 Sprocket Removal And Installation................................................366 Track Frame Removal And Installation.............................................367 Torsion Axle Removal And Installation............................................369 TRACK MAINTENANCE....................................................................371 Track Damage Identification......................................................371 MAINFRAME................................................................................383 SEAT BAR.............................................................................387 Description......................................................................387 Removal And Installation.........................................................388 Disassembly And Assembly.........................................................389 Compression Spring Disassembly And Assembly......................................390 OPERATOR CAB.........................................................................391 Gas Spring Removal And Installation..............................................391 Gas Spring Bracket Disassembly And Assembly......................................392 Removal And Installation.........................................................393 OPERATOR SEAT........................................................................395 Removal And Installation.........................................................395 Seat Belt Removal And Installation (Two Point)...................................395 Seat Belt Removal And Installation (Three Point).................................396 OPERATOR SEAT (SUSPENSION)...........................................................399 Removal And Installation.........................................................399 Slide Rail Removal And Installation..............................................399 Seat Belt Removal And Installation...............................................400 Lower Cushion Removal............................................................400 Lower Cushion Installation.......................................................401 Back Cushion Removal And Installation............................................401 Shock Removal And Installation...................................................402 3-Point Seat Belt Removal And Installation.......................................402 BOB-TACH (HAND LEVER)................................................................405 Description......................................................................405 Removal And Installation.........................................................405 Lever And Wedge Disassembly And Assembly.........................................407 Pivot Pin Bushing And Seal Removal And Installation..............................409 BOB-TACH (POWER).....................................................................411 Description......................................................................411 Removal And Installation.........................................................411 Lever And Wedge Disassembly And Assembly.........................................414 Pivot Pin Bushing And Seal Removal And Installation..............................415 LIFT ARMS............................................................................417 Driver Link Removal And Installation.............................................417 Follower Link Removal And Installation...........................................420 Lift Arm Removal And Installation................................................421 REAR GRILLE..........................................................................425 Raising Rear Grille..............................................................425 Lowering Rear Grille.............................................................426 Shield Removal And Installation..................................................426 REAR DOOR (TAILGATE).................................................................427 Removal And Installation.........................................................427 Striker Removal And Installation.................................................428 Striker Disassembly And Assembly.................................................428 Striker (Adjusting)..............................................................429 Latch Removal And Installation...................................................429 FUEL TANK............................................................................431 Removal And Installation.........................................................431 Fuel Level Sender Removal And Installation.......................................433 Fuel Tank Vent Removal And Installation..........................................434 CONTROL PEDALS (MANUAL)..............................................................435 Description......................................................................435 Pedal Removal And Installation (Right Side)......................................435 Pedal Removal And Installation (Left Side).......................................436 Pedal (Adjusting)................................................................436 FOOTREST (SJC).......................................................................437 Footrest Removal And Installation (Right Side)...................................437 Footrest Removal And Installation (Left Side)....................................437 CONTROL LEVER ASSEMBLY...............................................................439 Description......................................................................439 Linkage Removal And Installation.................................................440 Removal And Installation.........................................................441 Disassembly And Assembly.........................................................443 CONTROL LEVER CENTERING ASSEMBLY.....................................................445 Description......................................................................445 Disassembly And Assembly.........................................................446 Linkage Neutral (Adjusting)......................................................450 Linkage Travel (Adjusting).......................................................453 Shock Removal And Installation...................................................457 CONTROL HANDLE / LEVER (MANUAL)......................................................459 Description......................................................................459 Lever Removal And Installation...................................................460 CONTROL HANDLE (SJC).................................................................461 Description......................................................................461 Joystick Testing.................................................................461 Joystick Removal And Installation................................................462 ACCESS PANELS (LOWER)................................................................465 Removal And Installation (Left Side).............................................465 Removal And Installation (Right Side)............................................467 ACCESS PANELS (UPPER)................................................................469 Removal And Installation (Center Panel)..........................................469 Removal And Installation (Left Side).............................................470 Removal And Installation (Right Side)............................................471 WINDOW (REAR)........................................................................473 Removing Rear Window With Latches................................................473 Removing Rear Window With Rubber Cord............................................473 Removing Rear Window With Latches From Outside Loader............................474 Removing Rear Window With Latches From Outside Loader With Knob Kit..............474 Removing Rear Window With Rubber Cord From Outside Loader........................474 Disassembly And Assembly (Latches)...............................................475 Removal (Rubber Cord)............................................................476 Installation (Rubber Cord).......................................................477 WINDOW (TOP).........................................................................479 Removal And Installation.........................................................479 WINDOW (SIDE)........................................................................481 Removal And Installation.........................................................481 CAB DOOR.............................................................................483 Description......................................................................483 Removal And Installation.........................................................483 Disassembly And Assembly.........................................................484 Aligning.........................................................................486 Adjusting........................................................................486 Checking Operation...............................................................487 ARMREST..............................................................................489 Description......................................................................489 Removal And Installation.........................................................490 Disassembly And Assembly.........................................................492 HEADLINER............................................................................495 Removal And Installation.........................................................495 ELECTRICAL SYSTEM........................................................................499 ELECTRICAL SCHEMATICS................................................................505 ELECTRICAL SYSTEM....................................................................529 Glossary Of Electrical Symbols...................................................529 Electrical System Description....................................................532 Fuse And Relay Identification....................................................533 Solenoid Testing.................................................................537 BATTERY..............................................................................539 Removing And Installing Battery..................................................539 Battery Maintenance..............................................................540 Maintaining Battery Charge Level.................................................540 Battery Service During Machine Storage...........................................540 Testing Battery..................................................................541 Charging Battery.................................................................541 Using A Booster Battery (Jump Starting)..........................................542 ALTERNATOR...........................................................................543 Adjusting Belt (Machines Without Air Conditioning)...............................543 Replacing Belt (Machines Without Air Conditioning)...............................543 Adjusting Belt (Machines With Air Conditioning)..................................544 Replacing Belt (Machines With Air Conditioning)..................................544 Charging System Inspection.......................................................545 Alternator Voltage Testing.......................................................546 Low Voltage Testing..............................................................547 High Voltage Testing.............................................................547 Removal And Installation (Machines Without Air Conditioning).....................548 Removal And Installation (Machines With Air Conditioning)........................549 Parts Identification.............................................................550 STARTER..............................................................................551 Testing..........................................................................551 Removal And Installation.........................................................551 Parts Identification.............................................................552 INSTRUMENT PANEL IDENTIFICATION......................................................553 Instrument Panel Overview........................................................553 Standard Display.................................................................554 Touch Display....................................................................556 Left Control Panel...............................................................558 Right Control Panel..............................................................558 Jog Shuttle (Standard Display)...................................................559 Jog Shuttle (Touch Display)......................................................559 Heating, Ventilation, And Air Conditioning (HVAC) Controls.......................560 Touch Display Radio Input Ports..................................................560 Keyed Ignition Kit...............................................................561 Radio Identification.............................................................562 Left Switch Panel Removal And Installation.......................................564 Right Switch Panel Removal And Installation......................................565 LIGHTS...............................................................................567 Front Removal And Installation...................................................567 Rear Removal And Installation....................................................567 Cab Light Removal And Installation...............................................568 Side Light Removal And Installation..............................................568 BOBCAT HUB CONTROLLER................................................................569 Description......................................................................569 Connector Identification.........................................................570 Removal And Installation.........................................................573 BOBCAT MID CONTROLLER................................................................575 Description......................................................................575 Removal And Installation.........................................................576 BOBCAT CONTROLLER (SJC) (DRIVE)......................................................577 Description......................................................................577 Removal And Installation.........................................................578 ENGINE CONTROL UNIT (ECU)............................................................579 Description......................................................................579 Cleaning.........................................................................580 Removal And Installation.........................................................581 DIAGNOSTIC SERVICE CODES.............................................................583 Service Codes List...............................................................583 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..............................................589 Inspecting The Bobcat Interlock Control System (BICS™)...........................589 Inspecting The Lift Arm Bypass Control...........................................591 SEAT BAR SENSOR......................................................................593 Description......................................................................593 Troubleshooting..................................................................593 Testing..........................................................................594 Removal And Installation.........................................................595 Bobcat Interlock Control System (BICS™) Circuit Test.............................598 TRACTION LOCK........................................................................601 Description......................................................................601 Troubleshooting..................................................................602 Operating Parking Brake..........................................................603 Operating Hydraulic Controls With Parking Brake Engaged..........................603 CONTROL IDENTIFICATION...............................................................605 Identification Chart (Standard)..................................................605 Identification Chart (SJC).......................................................606 SERVICE PC (LAPTOP COMPUTER).........................................................607 Connecting Remote Start Tool (Service Tool)......................................607 CALIBRATION..........................................................................609 Description......................................................................609 Actuator Testing.................................................................609 Lift And Tilt Calibration (SJC)..................................................612 Adjusting Lift And Tilt Compensation.............................................612 Hydrostatic Pump Calibration (SJC)...............................................615 STEERING DRIFT COMPENSATION..........................................................621 Steering Drift Compensation Description..........................................621 Adjusting Steering Drift Compensation............................................622 NAVIGATION (STANDARD DISPLAY)........................................................625 Navigation Bar...................................................................625 Viewing Active Shortcuts.........................................................625 VITALS (STANDARD DISPLAY)............................................................627 Vital Detail And Machine Performance.............................................627 SERVICE (STANDARD DISPLAY)...........................................................629 Record A Service.................................................................629 SETTINGS (STANDARD DISPLAY)..........................................................631 Display Settings.................................................................631 Machine Settings.................................................................632 Language Settings................................................................633 Units............................................................................634 Software.........................................................................635 GAUGES (TOUCH DISPLAY)...............................................................637 Vital Detail And Machine Performance.............................................637 Notification Drawer..............................................................638 CAMERA (TOUCH DISPLAY)...............................................................639 Camera Settings..................................................................639 PHONE (TOUCH DISPLAY)................................................................641 AUDIO (TOUCH DISPLAY)................................................................643 SERVICE (TOUCH DISPLAY)..............................................................645 Record A Service.................................................................645 View Service Schedule............................................................646 View Service Record..............................................................647 View Service Codes...............................................................648 ATTACHMENTS (TOUCH DISPLAY)..........................................................649 Attachment Information...........................................................649 SETTINGS (TOUCH DISPLAY).............................................................651 Favorites........................................................................651 Display Settings.................................................................653 Machine Settings.................................................................654 Security Settings................................................................655 Security Settings (Manage Operators).............................................656 Operator Statistics..............................................................660 Job Clocks.......................................................................661 Language Settings................................................................663 Units............................................................................664 Camera Settings..................................................................664 Bluetooth® Settings..............................................................664 Audio Settings...................................................................664 Dealer...........................................................................665 Software.........................................................................666 PASSWORD SETUP.......................................................................667 Security Settings................................................................667 Security Settings (Manage Operators).............................................668 MAINTENANCE CLOCK....................................................................669 Record A Service.................................................................669 View Service Codes...............................................................670 BACK-UP ALARM SYSTEM.................................................................671 Inspecting Back-up Alarm System..................................................671 Troubleshooting (Joystick).......................................................672 Alarm Removal And Installation...................................................673 FRONT HORN...........................................................................675 Removal And Installation.........................................................675 Troubleshooting..................................................................676 ENGINE SPEED CONTROL (FOOT)..........................................................677 Description......................................................................677 Removal And Installation.........................................................677 Disassembly And Assembly.........................................................678 ENGINE SPEED CONTROL (HAND)..........................................................681 Description......................................................................681 Removal And Installation.........................................................682 ENGINE SPEED CONTROL (FOOT)..........................................................683 Description......................................................................683 Removal And Installation.........................................................683 Disassembly And Assembly.........................................................684 CAMSHAFT AND CRANKSHAFT POSITION SENSOR..............................................687 Removal And Installation.........................................................687 MACHINE IQ...........................................................................689 Description......................................................................689 Removal And Installation.........................................................689 Procedure........................................................................690 ENGINE SERVICE...........................................................................691 ENGINE INFORMATION...................................................................695 Description......................................................................695 Specifications...................................................................696 Sensor Location..................................................................698 Torque Values....................................................................705 Troubleshooting..................................................................707 Engine Removal And Installation..................................................709 Engine Mount Replacement.........................................................715 Compression - Testing............................................................717 Injector Signal - Testing........................................................719 Injector Signal - Testing (In-Line)..............................................721 Oil Pressure Testing (At Turbocharger Oil Inlet).................................723 DIESEL OXIDATION CATALYST (DOC)......................................................725 Removal And Installation.........................................................725 AIR CLEANER..........................................................................727 Housing Removal And Installation.................................................727 ENGINE COOLING SYSTEM................................................................729 Radiator Cooling Package Removal And Installation................................729 Hydraulic Fan Description........................................................733 Reversible Hydraulic Fan Description.............................................733 Hydraulic Fan Motor Assembly Removal And Installation............................734 Hydraulic Fan Motor Removal And Installation.....................................737 Hydraulic Fan Motor Disassembly And Assembly.....................................739 Water Pump Removal And Installation..............................................748 Thermostat Housing Removal And Installation......................................749 Testing The Thermostat...........................................................750 LUBRICATION SYSTEM...................................................................751 Description......................................................................751 Oil Pan Removal And Installation.................................................752 Oil Pump Removal And Installation................................................753 Oil Pump Relief Valve Description................................................754 Oil Pump Relief Valve Removal And Installation...................................754 Oil Cooler Removal And Installation..............................................754 Oil Filter Head Removal And Installation.........................................755 Oil Cooler Bypass Description....................................................757 Oil Cooler Bypass Removal And Installation.......................................757 FUEL SYSTEM..........................................................................759 Fuel Filter Housing Removal And Installation.....................................759 Fuel Lift Pump Removal And Installation..........................................761 Fuel Lift Pump Filter Removal And Installation...................................762 Transfer Pump / High Pressure Pump Removal And Installation......................762 Fuel Temperature Sensor Removal And Installation.................................764 Fuel Recirculation Valve (FRV) Removal And Installation..........................765 Fuel Pressure Relief Valve Removal And Installation..............................765 Fuel Rail Assembly Removal And Installation......................................766 Fuel Injector Removal And Installation...........................................767 Injector Coding..................................................................770 CYLINDER HEAD........................................................................773 Glow Plugs Testing...............................................................773 Glow Plug Removal And Installation...............................................774 Valve Clearance Adjustment.......................................................775 Cylinder Head Removal And Installation...........................................777 Cylinder Head Disassembly And Assembly...........................................780 Cylinder Head Inspection.........................................................781 Cylinder Head Top Clearance......................................................782 Valve Step Height................................................................783 Valve Stem Height................................................................783 Valve Guide......................................................................784 Valve............................................................................784 Valve Spring.....................................................................785 Rocker Arm Shaft Disassembly And Assembly........................................786 Rocker Arm Shaft Inspection......................................................787 Push Rod Inspection..............................................................787 CRANKSHAFT AND PISTONS...............................................................789 Piston And Connecting Rod Removal And Installation...............................789 Piston And Connecting Rod Inspection.............................................790 Crankshaft Removal And Installation..............................................792 Cylinder Block Inspection........................................................795 Crankshaft Inspection............................................................797 Connecting Rod Inspection........................................................797 Engine Component Class...........................................................798 CAMSHAFT.............................................................................801 Removal And Installation.........................................................801 Inspecting.......................................................................802 GEARCASE.............................................................................805 Gearcase Cover Removal And Installation..........................................805 Gear Backlash....................................................................806 Gear Timing......................................................................807 Idle Gear Removal And Installation...............................................808 Idle Gear Inspection.............................................................808 TURBOCHARGER.........................................................................809 Description......................................................................809 Removal And Installation.........................................................810 Inspection.......................................................................812 FLYWHEEL AND HOUSING.................................................................813 Flywheel Removal And Installation................................................813 Ring Gear Removal And Installation...............................................814 Housing Removal And Installation.................................................815 EXHAUST GAS RECIRCULATION (EGR) SYSTEM...............................................817 Description......................................................................817 Removal And Installation.........................................................818 EXHAUST MANIFOLD.....................................................................821 Removal And Installation.........................................................821 HEATING, VENTILATION AND AIR CONDITIONING (HVAC).........................................823 AIR CONDITIONING SYSTEM FLOW.........................................................825 Description......................................................................825 Chart............................................................................826 Components.......................................................................827 Safety Equipment.................................................................830 REGULAR MAINTENANCE..................................................................831 Cleaning HVAC Filters............................................................831 Cleaning Air Conditioning Evaporator And Heater Coil.............................832 Cleaning Air Conditioning Condenser..............................................833 Lubricating Air Conditioning System..............................................833 Troubleshooting HVAC System......................................................833 Adjusting Belt...................................................................834 Replacing Belt...................................................................834 Air Conditioning Service Chart...................................................835 TROUBLESHOOTING......................................................................837 Blower Motor Does Not Operate....................................................837 Blower Motor Operates Normally, But Air Flow Is Insufficient.....................837 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal.......837 The Compressor Does Not Operate At All, Or Operates Improperly...................837 Gauge Pressure Related Troubleshooting...........................................838 Troubleshooting Tree.............................................................840 Temperature / Pressure Chart.....................................................844 Poor A/C Performance.............................................................846 HVAC Repair And Leaks............................................................847 Electrical System................................................................848 Engine Coolant Bypassing The Heater Valve........................................854 Heater Valve Not Opening Or Closing..............................................855 SYSTEM CHARGING AND RECLAMATION......................................................857 Refrigerant Identification.......................................................857 Reclamation And Charging With Recovery / Charging Unit...........................858 COMPRESSOR...........................................................................861 Removal And Installation.........................................................861 Oil..............................................................................862 Oil Check........................................................................863 CONDENSER............................................................................865 Removal And Installation.........................................................865 RECEIVER / DRIER.....................................................................867 Receiver / Drier Removal And Installation........................................867 EVAPORATOR / HEATER UNIT.............................................................869 Removal And Installation.........................................................869 THERMOSTAT...........................................................................871 Description......................................................................871 Removal And Installation.........................................................872 EXPANSION VALVE......................................................................875 Removal And Installation.........................................................875 EVAPORATOR COIL......................................................................879 Removal And Installation.........................................................879 HEATER COIL..........................................................................883 Removal And Installation.........................................................883 BLOWER FAN...........................................................................885 Removal And Installation.........................................................885 Disassembly And Assembly.........................................................886 HEATER VALVE.........................................................................889 Removal And Installation.........................................................889 EVAPORATOR / HEATER COVER............................................................891 Removing.........................................................................891 Installing.......................................................................892 SPECIFICATIONS...........................................................................893 LOADER SPECIFICATIONS................................................................895 Machine Dimensions...............................................................895 Performance Specifications.......................................................897 Engine Specifications............................................................897 Drive System Specifications......................................................898 Control Specifications...........................................................898 Hydraulic System Specifications..................................................899 Hydraulic Cylinder Specifications................................................899 Electrical System Specifications.................................................900 Fluid Capacities.................................................................900 Tracks...........................................................................900 Ground Pressure..................................................................900 TECHINCAL SERVICE GUIDE SPECIFICATIONS...............................................901 Engine...........................................................................901 Engine Torques...................................................................901 Cooling System...................................................................901 Loader Torques...................................................................902 Hydraulic / Hydrostatic System...................................................902 Fuel Consumption.................................................................902 TORQUE SPECIFICATIONS FOR BOLTS......................................................903 Torque For General SAE Bolts.....................................................903 Torque For General Metric Bolts..................................................904 HYDRAULIC CONNECTION SPECIFICATIONS..................................................905 Straight Thread O-ring Fitting...................................................905 Flare Fitting....................................................................906 Tubelines And Hoses..............................................................906 HYDRAULIC FLUID SPECIFICATIONS.......................................................907 Specifications...................................................................907 CONVERSIONS..........................................................................909 Decimal And Millimeter Equivalent Chart..........................................909 U.S. To Metric Conversion Chart..................................................909 SERVICE TOOLS REQUIRED...............................................................911 Remote Start Tools...............................................................911 Hydraulic Tools..................................................................912 Mainframe And Drive Tools........................................................915 Electrical Tools.................................................................918 Engine Tools.....................................................................919 HVAC Tools.......................................................................924 ALPHABETICAL INDEX.......................................................................925
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