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Bobcat T66 Compact Track Loader Service Manual SN B51V11001 & Above – PDF DOWNLOAD
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Bobcat T66 Compact Track Loader Service Manual SN B51V11001 & Above – PDF DOWNLOAD
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Description
Bobcat T66 Compact Track Loader Service Manual SN B51V11001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat T66 Compact Track Loader Service Manual SN B51V11001 & Above – PDF DOWNLOAD
Language : English
Pages : 934
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T66 Compact Track Loader Service Manual SN B51V11001 & 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 B51V11001 & Above – PDF DOWNLOAD
MAINTENANCE SAFETY....................................................................... 3 CONTENTS................................................................................. 5 FOREWORD................................................................................. 7 FOREWORD............................................................................. 9 SAFETY INSTRUCTIONS.................................................................. 11 FIRE PREVENTION...................................................................... 13 Maintenance...................................................................... 13 Operation........................................................................ 13 Electrical....................................................................... 13 Hydraulic System................................................................. 13 Fueling.......................................................................... 13 Starting......................................................................... 13 Spark Arrester Exhaust System.................................................... 13 Welding And Grinding............................................................. 14 Fire Extinguishers............................................................... 14 SERIAL NUMBER LOCATIONS.............................................................. 15 Machine Serial Number Location................................................... 15 Engine Serial Number Location.................................................... 15 DELIVERY REPORT...................................................................... 16 LOADER IDENTIFICATION................................................................ 17 SAFETY & MAINTENANCE..................................................................... 19 LIFTING AND BLOCKING THE LOADER...................................................... 23 Procedure........................................................................ 23 LIFT ARM SUPPORT..................................................................... 25 Lift Arm Support Description..................................................... 25 Installing Lift Arm Support...................................................... 25 Removing Lift Arm Support........................................................ 27 OPERATOR CAB......................................................................... 29 Inspecting Operator Cab.......................................................... 29 Cab Door Sensor Description...................................................... 29 Raising Operator Cab............................................................. 30 Lowering Operator Cab............................................................ 31 Clear Side Enclosed Cab Option................................................... 33 Inspecting And Maintaining Clear Side Enclosed Cab Option........................ 33 Special Applications Kit......................................................... 33 Inspecting And Maintaining Special Applications Kit.............................. 34 Forestry Door And Window Kit..................................................... 34 Inspecting And Maintaining Forestry Door And Window Kit.......................... 34 TRANSPORTING THE LOADER ON A TRAILER................................................. 35 Loading And Unloading Machine.................................................... 35 Fastening Machine To Transport Vehicle........................................... 36 TOWING THE LOADER.................................................................... 37 Procedure........................................................................ 37 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....................................... 39 Description...................................................................... 39 Remote Start Tool (Service Tool) - 7022042....................................... 40 Loader Service Tool Harness - 6689747............................................ 41 Computer Service Tool Harness - 6689746.......................................... 42 Remote Start Procedure........................................................... 43 SERVICE SCHEDULE..................................................................... 47 Maintenance Intervals............................................................ 47 Service Schedule Symbols......................................................... 50 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 MACHINE LUBRICATION.................................................................. 87 Lubricating Grease Fittings...................................................... 87 PIVOT PINS........................................................................... 89 Checking Pivot Pin Torque........................................................ 89 LOADER STORAGE AND RETURN TO SERVICE................................................. 91 Loader Extended Storage Procedure................................................ 91 Loader Return To Service Procedure............................................... 91 STOPPING THE ENGINE AND LEAVING THE MACHINE.......................................... 93 EMERGENCY EXITS...................................................................... 95 Removing Rear Window With Latches................................................ 95 Removing Rear Window With Rubber Cord............................................ 95 Removing Rear Window With Latches From Outside Loader............................ 96 Removing Rear Window With Rubber Cord From Outside Loader........................ 97 Removing Front Door.............................................................. 97 Front Door Reassembly............................................................ 98 SEAT BELT............................................................................ 99 Inspection And Maintenance....................................................... 99 HYDRAULIC SYSTEM.........................................................................101 HYDRAULIC / HYDROSTATIC SCHEMATICS...................................................105 HYDRAULIC SYSTEM INFORMATION.........................................................113 Glossary Of Hydraulic Symbols....................................................113 Troubleshooting..................................................................117 CYLINDER (LIFT)......................................................................119 Testing..........................................................................119 Removal And Installation.........................................................120 Parts Identification.............................................................124 Disassembly......................................................................125 Assembly.........................................................................128 CYLINDER (TILT)......................................................................133 Testing..........................................................................133 Removal And Installation.........................................................134 Base End Pivot Pin Removal And Installation......................................136 Parts Identification.............................................................137 Disassembly......................................................................138 Assembly.........................................................................141 CYLINDER (BOB-TACH)..................................................................145 Testing..........................................................................145 Removal And Installation.........................................................146 Parts Identification.............................................................147 Disassembly......................................................................148 Assembly.........................................................................149 MAIN RELIEF VALVE....................................................................153 Description......................................................................153 Testing..........................................................................154 Main Relief Valve Removal And Installation.......................................156 HYDRAULIC CONTROL VALVE..............................................................157 Description......................................................................157 Removal And Installation.........................................................157 Actuator Removal And Installation................................................162 Identification Chart.............................................................165 Lift Load Check Valve Removal And Installation...................................166 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)...................168 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....168 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....169 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).....169 Port Relief Valve Removal And Installation.......................................170 Plug Removal And Installation....................................................171 End Cap Block Removal And Installation...........................................172 Lift Spool Removal And Installation..............................................172 Lift Spool Disassembly And Assembly..............................................174 Tilt Spool Removal And Installation..............................................175 Tilt Spool Disassembly And Assembly..............................................176 Auxiliary Spool Removal And Installation.........................................177 Solenoid Removal And Installation................................................178 Solenoid Removal And Installation................................................179 BICS™ Lock Valve Removal And Installation........................................179 Lift Arm Bypass Orifice Removal And Installation.................................181 Main Relief Valve Removal And Installation.......................................181 Screen Fitting Removal And Installation..........................................182 LIFT ARM BYPASS CONTROL VALVE........................................................183 Description......................................................................183 Testing..........................................................................183 Removal And Installation.........................................................184 Bracket Removal And Installation.................................................185 Disassembly And Assembly.........................................................185 HYDRAULIC PUMP.......................................................................187 Description......................................................................187 Pump Test At Quick Couplers......................................................188 Direct Pump Test (Standard Section)..............................................189 Direct Pump Test (Charge Section)................................................191 Removal And Installation.........................................................193 Hydraulic Pump Startup...........................................................196 Parts Identification.............................................................197 Disassembly And Assembly.........................................................198 HYDRAULIC PUMP (HIGH FLOW)...........................................................199 Description......................................................................199 Direct Pump Test (Standard Section)..............................................201 Direct Pump Test (Charge Section)................................................202 Direct Pump Test (High Flow Section).............................................204 High Flow Relief Valve Adjustment................................................206 High Flow Relief Valve Removal And Installation..................................207 Solenoid Removal And Installation................................................208 Removal And Installation.........................................................209 Hydraulic Pump Startup...........................................................212 Parts Identification.............................................................213 Disassembly And Assembly.........................................................214 HYDRAULIC FILTERS....................................................................215 Description......................................................................215 Housing Removal And Installation.................................................215 HYDRAULIC FLUID RESERVOIR............................................................217 Description......................................................................217 Removal And Installation.........................................................218 OIL COOLER...........................................................................221 Description......................................................................221 Removal And Installation.........................................................221 BUCKET POSITION SENSORS..............................................................223 Description......................................................................223 Removal And Installation.........................................................223 REAR AUXILIARY DIVERTER VALVE........................................................225 Description......................................................................225 Removal And Installation.........................................................225 Disassembly And Assembly.........................................................228 BOB-TACH (POWER) BLOCK...............................................................233 Description......................................................................233 Testing Relief Valve.............................................................234 Removal And Installation.........................................................236 Disassembly And Assembly.........................................................238 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK..............................................243 Description......................................................................243 Removal And Installation.........................................................244 Disassembly And Assembly.........................................................245 AUTOMATIC RIDE CONTROL...............................................................247 Description......................................................................247 Removal And Installation.........................................................248 Checking The Pressure In The Accumulator.........................................250 Adding Nitrogen To The Accumulator...............................................252 HYDROSTATIC SYSTEM.......................................................................255 HYDROSTATIC SYSTEM INFORMATION.......................................................257 Description......................................................................257 Troubleshooting..................................................................257 HYDROSTATIC DRIVE MOTOR..............................................................259 Description......................................................................259 Removing And Replacing Fluid.....................................................259 Removal And Installation.........................................................260 Parts Identification (MCR5T) (One-Speed).........................................263 Parts Identification (MCR6T) (Two-Speed).........................................264 Disassembly And Assembly.........................................................265 CHARGE PRESSURE......................................................................275 Description......................................................................275 Testing..........................................................................275 Sender Removal And Installation..................................................277 Adjusting And Inspecting (SJC)...................................................278 HYDROSTATIC PUMP (MANUAL)............................................................279 Description......................................................................279 Port Locations And Gauge Installation............................................280 Removal And Installation.........................................................281 Hydrostatic Pump Startup.........................................................283 Disassembly And Assembly.........................................................284 HYDROSTATIC PUMP (SJC)...............................................................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 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................................................................503 ELECTRICAL SYSTEM....................................................................527 Glossary Of Electrical Symbols...................................................527 Standard Cab Harness Connectors..................................................530 Deluxe Cab Harness Connectors....................................................531 Mainframe Harness Connectors.....................................................532 Electrical System Description....................................................533 Fuse And Relay Identification....................................................534 Solenoid Testing.................................................................538 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 (HAND)..........................................................677 Description......................................................................677 Removal And Installation.........................................................678 ENGINE SPEED CONTROL (FOOT)..........................................................679 Description......................................................................679 Removal And Installation.........................................................679 Disassembly And Assembly.........................................................680 CAMSHAFT AND CRANKSHAFT POSITION SENSOR..............................................683 Removal And Installation.........................................................683 MACHINE IQ...........................................................................685 Description......................................................................685 Removal And Installation.........................................................685 Procedure........................................................................686 ENGINE SERVICE...........................................................................687 ENGINE INFORMATION...................................................................691 Description......................................................................691 Specifications...................................................................692 Sensor Location..................................................................694 Torque Values....................................................................701 Troubleshooting..................................................................703 Engine Removal And Installation..................................................705 Engine Mount Replacement.........................................................711 Compression - Testing............................................................713 Injector Signal - Testing........................................................715 Oil Pressure Testing (At Turbocharger Oil Inlet).................................717 DIESEL PARTICULATE FILTER (DPF) SYSTEM...............................................719 Description......................................................................719 DPF Regeneration Status Icons....................................................719 DPF Regeneration Tables..........................................................720 Removal And Installation.........................................................722 Automatic Regeneration Operation.................................................724 Forced Regeneration Operation....................................................725 Forced Parked Regeneration Operation.............................................726 Inhibit Mode Operation...........................................................728 AIR CLEANER..........................................................................731 Housing Removal And Installation.................................................731 ENGINE COOLING SYSTEM................................................................733 Radiator Cooling Package Removal And Installation................................733 Hydraulic Fan Description........................................................737 Reversible Hydraulic Fan Description.............................................737 Hydraulic Fan Motor Assembly Removal And Installation............................738 Hydraulic Fan Motor Removal And Installation.....................................741 Hydraulic Fan Motor Disassembly And Assembly.....................................743 Water Pump Removal And Installation..............................................751 Thermostat Housing Removal And Installation......................................752 Testing The Thermostat...........................................................753 LUBRICATION SYSTEM...................................................................755 Description......................................................................755 Oil Pan Removal And Installation.................................................756 Oil Pump Removal And Installation................................................757 Oil Pump Relief Valve Description................................................758 Oil Pump Relief Valve Removal And Installation...................................758 Oil Cooler Removal And Installation..............................................758 Oil Filter Head Removal And Installation.........................................759 Oil Cooler Bypass Description....................................................761 Oil Cooler Bypass Removal And Installation.......................................761 FUEL SYSTEM..........................................................................763 Description......................................................................763 Fuel Filter Housing Removal And Installation.....................................764 Fuel Lift Pump Removal And Installation..........................................766 Fuel Lift Pump Filter Removal And Installation...................................767 Transfer Pump / High Pressure Pump Removal And Installation......................767 Fuel Temperature Sensor Removal And Installation.................................769 Fuel Recirculation Valve (FRV) Removal And Installation..........................770 Fuel Pressure Relief Valve Removal And Installation..............................770 Fuel Rail Assembly Removal And Installation......................................771 Fuel Injector Removal And Installation...........................................772 Injector Coding..................................................................776 CYLINDER HEAD........................................................................779 Glow Plugs Testing...............................................................779 Glow Plug Removal And Installation...............................................780 Cylinder Head Removal And Installation...........................................781 Cylinder Head Disassembly And Assembly...........................................784 Cylinder Head Inspection.........................................................785 Cylinder Head Top Clearance......................................................786 Valve Step Height................................................................787 Valve Stem Height................................................................787 Valve Guide......................................................................788 Valve............................................................................788 Valve Spring.....................................................................789 Rocker Arm Shaft Disassembly And Assembly........................................790 Rocker Arm Shaft Inspection......................................................791 Push Rod Inspection..............................................................791 CRANKSHAFT AND PISTONS...............................................................793 Piston And Connecting Rod Removal And Installation...............................793 Piston And Connecting Rod Inspection.............................................794 Crankshaft Removal And Installation..............................................796 Cylinder Block Inspection........................................................799 Crankshaft Inspection............................................................801 Connecting Rod Inspection........................................................801 Engine Component Class...........................................................802 CAMSHAFT.............................................................................805 Removal And Installation.........................................................805 Inspecting.......................................................................806 GEARCASE.............................................................................809 Gearcase Cover Removal And Installation..........................................809 Gear Backlash....................................................................810 Gear Timing......................................................................811 Idle Gear Removal And Installation...............................................812 Idle Gear Inspection.............................................................812 TURBOCHARGER.........................................................................813 Description......................................................................813 Removal And Installation.........................................................813 Inspection.......................................................................815 FLYWHEEL AND HOUSING.................................................................817 Flywheel Removal And Installation................................................817 Ring Gear Removal And Installation...............................................818 Housing Removal And Installation.................................................819 EXHAUST GAS RECIRCULATION (EGR) SYSTEM...............................................821 Description......................................................................821 Removal And Installation.........................................................822 EXHAUST MANIFOLD.....................................................................825 Removal And Installation.........................................................825 HEATING, VENTILATION AND AIR CONDITIONING (HVAC).........................................827 AIR CONDITIONING SYSTEM FLOW.........................................................829 Description......................................................................829 Chart............................................................................830 Components.......................................................................831 Safety Equipment.................................................................834 REGULAR MAINTENANCE..................................................................835 Cleaning HVAC Filters............................................................835 Cleaning Air Conditioning Evaporator And Heater Coil.............................836 Cleaning Air Conditioning Condenser..............................................837 Lubricating Air Conditioning System..............................................837 Troubleshooting HVAC System......................................................837 Adjusting Belt...................................................................838 Replacing Belt...................................................................838 Air Conditioning Service Chart...................................................839 TROUBLESHOOTING......................................................................841 Blower Motor Does Not Operate....................................................841 Blower Motor Operates Normally, But Air Flow Is Insufficient.....................841 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal.......841 The Compressor Does Not Operate At All, Or Operates Improperly...................841 Gauge Pressure Related Troubleshooting...........................................842 Troubleshooting Tree.............................................................844 Temperature / Pressure Chart.....................................................848 Poor A/C Performance.............................................................850 HVAC Repair And Leaks............................................................851 Electrical System................................................................852 Engine Coolant Bypassing The Heater Valve........................................858 Heater Valve Not Opening Or Closing..............................................859 SYSTEM CHARGING AND RECLAMATION......................................................861 Refrigerant Identification.......................................................861 Reclamation And Charging With Recovery / Charging Unit...........................862 COMPRESSOR...........................................................................865 Removal And Installation.........................................................865 Oil..............................................................................866 Oil Check........................................................................867 CONDENSER............................................................................869 Removal And Installation.........................................................869 RECEIVER / DRIER.....................................................................871 Receiver / Drier Removal And Installation........................................871 EVAPORATOR / HEATER UNIT.............................................................873 Removal And Installation.........................................................873 THERMOSTAT...........................................................................875 Description......................................................................875 Removal And Installation.........................................................876 EXPANSION VALVE......................................................................879 Removal And Installation.........................................................879 EVAPORATOR COIL......................................................................883 Removal And Installation.........................................................883 HEATER COIL..........................................................................887 Removal And Installation.........................................................887 BLOWER FAN...........................................................................889 Removal And Installation.........................................................889 Disassembly And Assembly.........................................................890 HEATER VALVE.........................................................................893 Removal And Installation.........................................................893 EVAPORATOR / HEATER COVER............................................................895 Removing.........................................................................895 Installing.......................................................................896 SPECIFICATIONS...........................................................................897 LOADER SPECIFICATIONS................................................................899 Machine Dimensions...............................................................899 Performance Specifications.......................................................901 Engine Specifications............................................................901 Drive System Specifications......................................................902 Control Specifications...........................................................902 Hydraulic System Specifications..................................................903 Hydraulic Cylinder Specifications................................................903 Electrical System Specifications.................................................904 Fluid Capacities.................................................................904 Tracks...........................................................................904 Ground Pressure..................................................................904 Engine CO2 Emission Values.......................................................904 TECHINCAL SERVICE GUIDE SPECIFICATIONS...............................................905 Engine...........................................................................905 Engine Torques...................................................................905 Cooling System...................................................................905 Loader Torques...................................................................906 Hydraulic / Hydrostatic System...................................................906 Fuel Consumption.................................................................906 TORQUE SPECIFICATIONS FOR BOLTS......................................................907 Torque For General SAE Bolts.....................................................907 Torque For General Metric Bolts..................................................908 HYDRAULIC CONNECTION SPECIFICATIONS..................................................909 Straight Thread O-ring Fitting...................................................909 Flare Fitting....................................................................910 Tubelines And Hoses..............................................................910 HYDRAULIC FLUID SPECIFICATIONS.......................................................911 Specifications...................................................................911 CONVERSIONS..........................................................................913 Decimal And Millimeter Equivalent Chart..........................................913 U.S. To Metric Conversion Chart..................................................913 SERVICE TOOLS REQUIRED...............................................................915 Remote Start Tools...............................................................915 Hydraulic Tools..................................................................916 Mainframe And Drive Tools........................................................919 Electrical Tools.................................................................922 Engine Tools.....................................................................923 HVAC Tools.......................................................................928 ALPHABETICAL INDEX.......................................................................929
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V
