Complete repair service manual with electrical wiring diagrams for Bobcat T550, T590, T630, T650 Compact Track Loaders, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Bobcat T550, T590, T630, T650 Compact Track Loaders workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6987163 (3-11) - T630 Compact Track Loader Operation & Maintenance Manual.pdf
6987163 (11-10) - T630 Compact Track Loader Operation & Maintenance Manual.pdf
6987164 (10-10) - T630 Compact Track Loader Service Manual.pdf
6987164 (12-13) - T630 Compact Track Loader Service Manual.pdf
6987171 (3-11) - T650 Compact Track Loader Operation & Maintenance Manual.pdf
6987171 (11-10) - T650 Compact Track Loader Operation & Maintenance Manual.pdf
6987172 (05-14) - T650 Compact Track Loader Service Manual.pdf
6987172 (12-10) - T650 Compact Track Loader Service Manual.pdf
6989679 (08-12) - T550 Compact Track Loader Service Manual.pdf
6989683 (08-12) - T590 Compact Track Loader Service Manual.pdf
6990689 (10-13) - T550 Compact Track Loader Service Manual.pdf
6990693 (10-13) - T590 Compact Track Loader Service Manual.pdf
6990751 (02-14) - T630 Compact Track Loader Service Manual.pdf
6990755 (12-14) - T650 Compact Track Loader Service Manual.pdf

Total Pages: 10,622 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
SAFETY & MAINTENANCE . . . . 10-01
HYDRAULIC SYSTEM . . . . 20-01
HYDROSTATIC SYSTEM . . . 30-01
DRIVE SYSTEM . . . 40-01
MAINFRAME . . . 50-01
ELECTRICAL SYSTEM & ANALYSIS . . . . 60-01
ENGINE SERVICE . . . 70-01
HEATING, VENTILATION, AIR CONDITIONING . . . . 80-01
SPECIFICATIONS . . . . SPEC-01
ALPHABETICAL INDEX . . . .INDEX-01

6987163 (11-10) - T630 Compact Track Loader Operation & Maintenance Manual....2
  OPERATOR SAFETY WARNINGS....4
  CONTENTS....6
  FOREWORD....8
    BOBCAT COMPANY IS IS0 9001 CERTIFIED....10
    REGULAR MAINTENANCE ITEMS....10
    SERIAL NUMBER LOCATIONS....11
      Loader Serial Number....11
      Engine Serial Number....11
    DELIVERY REPORT....11
    LOADER IDENTIFICATION....12
    FEATURES, ACCESSORIES AND ATTACHMENTS....13
      Standard Items....13
      Options And Accessories....13
      Buckets Available....14
      Attachments....14
      High-Flow Attachments....14
      Special Applications Kit....15
      Special Applications Kit Inspection And Maintenance....15
  SAFETY & TRAINING RESOURCES....16
    SAFETY INSTRUCTIONS....18
      Before Operation....18
      Safe Operation Is The Operators Responsibility....19
      Safe Operation Needs A Qualified Operator....19
      Avoid Silica Dust....20
    FIRE PREVENTION....20
      Maintenance....20
      Operation....20
      Electrical....20
      Hydraulic System....21
      Fueling....21
      Starting....21
      Spark Arrestor Exhaust System....21
      Welding And Grinding....21
      Fire Extinguishers....21
    PUBLICATIONS AND TRAINING RESOURCES....22
    MACHINE SIGNS (DECALS)....23
      No-Text Safety Signs....26
  OPERATING INSTRUCTIONS....28
    INSTRUMENT PANEL IDENTIFICATION....32
      Overview....32
      Left Panel....33
      Display Screen....35
      Right Panel (Standard Key Panel)....36
      Right Panel (Keyless Start Panel)....37
      Right Panel (Deluxe Instrumentation Panel)....38
      Left Switch Panel....40
      Right Switch Panel....40
      Left Side Lower Panel....41
      Right Side Lower Panel....41
      Radio....42
    CONTROL IDENTIFICATION....44
      Standard Controls....44
      Advanced Control System (ACS)....45
      Selectable Joystick Controls (SJC)....46
    OPERATOR CAB....47
      Description....47
      Cab Light....47
      Door Operation....47
      Front Wiper....48
      Side Windows....48
    SEAT BAR RESTRAINT SYSTEM....49
      Operation....49
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....50
      Operation....50
    LIFT ARM BYPASS CONTROL....51
      Operation....51
    PARKING BRAKE....51
      Operation....51
    TRACTION LOCK OVERRIDE....52
      Operation....52
    ENGINE SPEED CONTROL....52
      Operation....52
    EMERGENCY EXIT....53
      External Access....53
      Rear Window....53
      Front Door....53
    BACK-UP ALARM SYSTEM....55
      Description....55
      Operation....55
    DRIVING AND STEERING THE LOADER....56
      Available Control Configurations....56
      Operation (Standard And ACS)....56
      Operation (SJC) In ISO Control Pattern....57
      Operation (SJC) In H Control Pattern....58
    STOPPING THE LOADER....58
      Using The Control Levers Or Joysticks....58
    TWO-SPEED CONTROL....59
      Description....59
      Operation (Standard And ACS) (If Equipped)....59
      Operation (SJC) (If Equipped)....59
    SPEED MANAGEMENT....60
      Operation....60
      Changing The Factory Default Setting....61
    DRIVE RESPONSE....62
      Description....62
      Operation....62
    STEERING DRIFT COMPENSATION....64
      Description....64
      Operation....64
    HYDRAULIC CONTROLS....66
      Description....66
      Standard Controls (Also ACS In FOOT Pedal Mode)....66
      Advanced Control System (ACS) In HAND Control Mode....67
      Selectable Joystick Controls (SJC) In ISO Control Pattern....67
      Selectable Joystick Controls (SJC) In H Control Pattern....68
      Hydraulic Bucket Positioning....68
      FRONT Auxiliary Hydraulics Operation....69
      FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....70
      FRONT Auxiliary Hydraulics Operation (REVERSE CONTINUOUS FLOW)....70
      REAR Auxiliary Hydraulics Operation....71
      High-Flow Hydraulics Operation....72
      Quick Couplers....72
      Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....73
    ATTACHMENT CONTROL DEVICE (ACD)....74
      Description....74
    DAILY INSPECTION....75
      Daily Inspection And Maintenance....75
    PRE-STARTING PROCEDURE....77
      Entering The Loader....77
      Operation & Maintenance Manual And Operators Handbook Locations....77
      Seat Adjustment....78
      Joystick Position Adjustment....79
      Seat Belt Adjustment....80
      Seat Bar....80
    STARTING THE ENGINE....81
      Standard Key Panel....81
      Keyless Start Panel....83
      Deluxe Instrumentation Panel....85
      Cold Temperature Starting....87
      Warming The Hydraulic / Hydrostatic System....87
    MONITORING THE DISPLAY PANELS....88
      Left Panel....88
      Warning And Shutdown....88
    STOPPING THE ENGINE AND LEAVING THE LOADER....89
      Procedure....89
    COUNTERWEIGHTS....90
      Description....90
      Effect On The Loader And Loader Operation....90
      When To Consider Using Counterweights....90
      When To Consider Removing Counterweights....90
      Accessories That Affect Machine Weight....90
    ATTACHMENTS....91
      Choosing The Correct Bucket....91
      Pallet Fork....91
      Installing And Removing The Attachment (Hand Lever Bob-Tach)....92
      Installing And Removing The Attachment (Power Bob-Tach)....94
    TRACK UNDERCARRIAGE SYSTEM....99
      Introduction....99
      Compact Track Loader Operating And Maintenance Tips....99
    OPERATING PROCEDURE....101
      Inspect The Work Area....101
      Basic Operating Instructions....101
      Driving On Public Roads....101
      Operating With A Full Bucket....102
      Operating With An Empty Bucket....102
      Filling And Emptying The Bucket (Foot Pedals)....103
      Leveling The Ground Using Float (Foot Pedals)....104
      Digging And Filling A Hole (Foot Pedals)....104
      Filling And Emptying The Bucket (ACS - Handles, SJC - H Pattern)....105
      Leveling The Ground Using Float (ACS - Handles, SJC - H Pattern)....106
      Digging And Filling A Hole (ACS - Handles, SJC - H Pattern)....107
      Filling And Emptying The Bucket (SJC - ISO Pattern)....108
      Leveling The Ground Using Float (SJC - ISO Pattern)....109
      Digging And Filling A Hole (SJC - ISO Pattern)....110
    TOWING THE LOADER....111
      Procedure....111
    LIFTING THE LOADER....111
      Single-Point Lift....111
      Four-Point Lift....112
    TRANSPORTING THE LOADER ON A TRAILER....113
      Loading And Unloading....113
      Fastening....113
  PREVENTIVE MAINTENANCE....114
    MAINTENANCE SAFETY....118
    SERVICE SCHEDULE....120
      Chart....120
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....121
      Inspecting The BICS (Engine STOPPED - Key ON)....121
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....121
      Inspecting The Seat Bar Sensor (Engine RUNNING)....121
      Inspecting The Traction Lock (Engine RUNNING)....121
      Inspecting The Lift Arm Bypass Control....121
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....121
    SEAT BAR RESTRAINT SYSTEM....122
      Description....122
      Inspecting....122
      Maintaining....122
    SEAT BELT....123
      Inspection And Maintenance....123
    LIFT ARM SUPPORT DEVICE....124
      Installing....124
      Removing....125
    BACK-UP ALARM SYSTEM....126
      Description....126
      Inspecting....126
      Adjusting Switch Position....127
    OPERATOR CAB....128
      Description....128
      Raising....128
      Lowering....129
      Cab Door Sensor....130
    REAR DOOR (TAILGATE)....131
      Opening And Closing....131
      Adjusting....131
    REAR GRILLE....132
      Removing....132
      Installing....132
    HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....133
      Cleaning And Maintenance....133
      Filters....133
      Evaporator / Heater Coil....134
      Condenser....135
      Air Conditioning Lubrication....135
      Troubleshooting....135
    AIR CLEANER SERVICE....135
      Replacing Filter Elements....135
    FUEL SYSTEM....137
      Fuel Specifications....137
      Biodiesel Blend Fuel....137
      Filling The Fuel Tank....138
      Fuel Filter....139
      Removing Air From The Fuel System....139
    ENGINE LUBRICATION SYSTEM....140
      Checking And Adding Engine Oil....140
      Engine Oil Chart....140
      Removing And Replacing Oil And Filter....141
    ENGINE COOLING SYSTEM....142
      Maintenance Platform....142
      Cleaning....142
      Checking Level....144
      Removing And Replacing Coolant....144
    ELECTRICAL SYSTEM....145
      Description....145
      Fuse And Relay Location / Identification....145
      Battery Maintenance....148
      Using A Booster Battery (Jump Starting)....149
      Removing And Installing Battery....150
    HYDRAULIC / HYDROSTATIC SYSTEM....151
      Checking And Adding Fluid....151
      Hydraulic / Hydrostatic Fluid Chart....151
      Removing And Replacing Hydraulic Fluid....152
      Removing And Replacing Hydraulic / Hydrostatic Filter....154
      Removing And Replacing Hydraulic Charge Filter....156
      Breather Cap....157
    SPARK ARRESTER MUFFLER....158
      Cleaning Procedure....158
    TRACK TENSION....159
      Description....159
      Checking (Solid-Mounted Undercarriage)....160
      Adjusting (Solid-Mounted Undercarriage)....161
      Checking (Roller Suspension Undercarriage)....162
      Adjusting (Roller Suspension Undercarriage)....163
    HYDROSTATIC DRIVE MOTOR....164
      Removing And Replacing Oil....164
    TRACK SPROCKET MAINTENANCE....164
      Tightening Procedure....164
    ALTERNATOR BELT....165
      Belt Adjustment....165
      Belt Replacement....165
    AIR CONDITIONING BELT....166
      Belt Adjustment....166
      Belt Replacement....166
    DRIVE BELT....167
      Belt Adjustment....167
      Stop Adjustment....167
      Belt Replacement....167
    LUBRICATING THE LOADER....169
      Lubrication Locations....169
    TRACK ROLLER AND IDLER LUBRICATION....171
      Procedure....171
    PIVOT PINS....171
      Inspection And Maintenance....171
    BOB-TACH (HAND LEVER)....172
      Inspection And Maintenance....172
    BOB-TACH (POWER)....173
      Inspection And Maintenance....173
    LOADER STORAGE AND RETURN TO SERVICE....174
      Storage....174
      Return To Service....174
  SYSTEM SETUP & ANALYSIS....176
    DIAGNOSTIC SERVICE CODES....178
      Viewing Service Codes....178
      Service Codes List....179
    CONTROL PANEL SETUP....184
      Right Panel Setup (Deluxe Instrumentation Panel)....184
    PASSWORD SETUP (KEYLESS START PANEL)....186
      Password Description....186
      Changing The Owner Password....186
      Password Lockout Feature....186
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....187
      Password Description....187
      Changing The Owner Password....187
      Changing The User Passwords....188
      Password Lockout Feature....188
    MAINTENANCE CLOCK....189
      Description....189
      Setup....189
      Reset....189
  MACHINE SIGN TRANSLATIONS....190
    MACHINE SIGN TRANSLATIONS....192
      Service Schedule (7167998)....192
      Warning (7167993)....195
      Warning (7169291)....195
      Danger (7167989)....195
      Danger (7167990)....195
      Danger (7167988)....196
      Warning (7168114)....196
      Warning (7167994)....197
      Warning (7168140)....198
      Warning (7168142)....198
      Warning (7168138)....199
      Warning (7167996)....200
      Warning (7167995)....200
      Warning (7184346)....201
      Danger (7170355)....201
      Warning (6737189)....202
      Lift Arm Support Device (6706558)....203
      Warning (7168024)....204
      Warning (7142141)....205
      Warning (7168019)....206
  SPECIFICATIONS....208
    (T630) LOADER SPECIFICATIONS....210
      Machine Dimensions....210
      Performance....211
      Engine....211
      Drive System....211
      Controls....212
      Hydraulic System....212
      Electrical System....213
      Capacities....213
      Tracks....213
      Ground Pressure....213
  WARRANTY....214
    WARRANTY....216
  ALPHABETICAL INDEX....218
6987163 (3-11) - T630 Compact Track Loader Operation & Maintenance Manual....220
  OPERATOR SAFETY WARNINGS....222
  CONTENTS....224
  FOREWORD....226
    BOBCAT COMPANY IS IS0 9001 CERTIFIED....228
    REGULAR MAINTENANCE ITEMS....228
    SERIAL NUMBER LOCATIONS....229
      Loader Serial Number....229
      Engine Serial Number....229
    DELIVERY REPORT....229
    LOADER IDENTIFICATION....230
    FEATURES, ACCESSORIES AND ATTACHMENTS....231
      Standard Items....231
      Options And Accessories....231
      Buckets Available....232
      Attachments....232
      High-Flow Attachments....232
      Special Applications Kit....233
      Special Applications Kit Inspection And Maintenance....233
  SAFETY & TRAINING RESOURCES....234
    SAFETY INSTRUCTIONS....236
      Before Operation....236
      Safe Operation Is The Operators Responsibility....237
      Safe Operation Needs A Qualified Operator....237
      Avoid Silica Dust....238
    FIRE PREVENTION....238
      Maintenance....238
      Operation....238
      Electrical....238
      Hydraulic System....239
      Fueling....239
      Starting....239
      Spark Arrestor Exhaust System....239
      Welding And Grinding....239
      Fire Extinguishers....239
    PUBLICATIONS AND TRAINING RESOURCES....240
    MACHINE SIGNS (DECALS)....241
      No-Text Safety Signs....244
  OPERATING INSTRUCTIONS....246
    INSTRUMENT PANEL IDENTIFICATION....250
      Overview....250
      Left Panel....251
      Display Screen....253
      Right Panel (Standard Key Panel)....254
      Right Panel (Keyless Start Panel)....255
      Right Panel (Deluxe Instrumentation Panel)....256
      Left Switch Panel....258
      Right Switch Panel....258
      Left Side Lower Panel....259
      Right Side Lower Panel....259
      Radio....260
    CONTROL IDENTIFICATION....262
      Standard Controls....262
      Advanced Control System (ACS)....263
      Selectable Joystick Controls (SJC)....264
    OPERATOR CAB....265
      Description....265
      Cab Light....265
      Door Operation....265
      Front Wiper....266
      Side Windows....266
    SEAT BAR RESTRAINT SYSTEM....267
      Operation....267
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....268
      Operation....268
    LIFT ARM BYPASS CONTROL....269
      Operation....269
    PARKING BRAKE....269
      Operation....269
    TRACTION LOCK OVERRIDE....270
      Operation....270
    ENGINE SPEED CONTROL....270
      Operation....270
    EMERGENCY EXIT....271
      External Access....271
      Rear Window....271
      Front Door....271
    BACK-UP ALARM SYSTEM....273
      Description....273
      Operation....273
    DRIVING AND STEERING THE LOADER....274
      Available Control Configurations....274
      Operation (Standard And ACS)....274
      Operation (SJC) In ISO Control Pattern....275
      Operation (SJC) In H Control Pattern....276
    STOPPING THE LOADER....276
      Using The Control Levers Or Joysticks....276
    TWO-SPEED CONTROL....277
      Description....277
      Operation (Standard And ACS) (If Equipped)....277
      Operation (SJC) (If Equipped)....277
    SPEED MANAGEMENT....278
      Operation....278
      Changing The Factory Default Setting....279
    DRIVE RESPONSE....280
      Description....280
      Operation....280
    STEERING DRIFT COMPENSATION....282
      Description....282
      Operation....282
    HYDRAULIC CONTROLS....284
      Description....284
      Standard Controls (Also ACS In FOOT Pedal Mode)....284
      Advanced Control System (ACS) In HAND Control Mode....285
      Selectable Joystick Controls (SJC) In ISO Control Pattern....285
      Selectable Joystick Controls (SJC) In H Control Pattern....286
      Hydraulic Bucket Positioning....286
      FRONT Auxiliary Hydraulics Operation....287
      FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....288
      FRONT Auxiliary Hydraulics Operation (REVERSE CONTINUOUS FLOW)....288
      REAR Auxiliary Hydraulics Operation....289
      High-Flow Hydraulics Operation....290
      Quick Couplers....290
      Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....291
    ATTACHMENT CONTROL DEVICE (ACD)....292
      Description....292
    DAILY INSPECTION....293
      Daily Inspection And Maintenance....293
    PRE-STARTING PROCEDURE....295
      Entering The Loader....295
      Operation & Maintenance Manual And Operators Handbook Locations....295
      Seat Adjustment....296
      Joystick Position Adjustment....297
      Seat Belt Adjustment....298
      Seat Bar....298
    STARTING THE ENGINE....299
      Standard Key Panel....299
      Keyless Start Panel....301
      Deluxe Instrumentation Panel....303
      Cold Temperature Starting....305
      Warming The Hydraulic / Hydrostatic System....305
    MONITORING THE DISPLAY PANELS....306
      Left Panel....306
      Warning And Shutdown....306
    STOPPING THE ENGINE AND LEAVING THE LOADER....307
      Procedure....307
    COUNTERWEIGHTS....308
      Description....308
      Effect On The Loader And Loader Operation....308
      When To Consider Using Counterweights....308
      When To Consider Removing Counterweights....308
      Accessories That Affect Machine Weight....308
    ATTACHMENTS....309
      Choosing The Correct Bucket....309
      Pallet Fork....309
      Installing And Removing The Attachment (Hand Lever Bob-Tach)....310
      Installing And Removing The Attachment (Power Bob-Tach)....312
    TRACK UNDERCARRIAGE SYSTEM....317
      Introduction....317
      Compact Track Loader Operating And Maintenance Tips....317
    OPERATING PROCEDURE....319
      Inspect The Work Area....319
      Basic Operating Instructions....319
      Driving On Public Roads....319
      Operating With A Full Bucket....320
      Operating With An Empty Bucket....320
      Filling And Emptying The Bucket (Foot Pedals)....321
      Leveling The Ground Using Float (Foot Pedals)....322
      Digging And Filling A Hole (Foot Pedals)....323
      Filling And Emptying The Bucket (ACS - Handles, SJC - H Pattern)....324
      Leveling The Ground Using Float (ACS - Handles, SJC - H Pattern)....325
      Digging And Filling A Hole (ACS - Handles, SJC - H Pattern)....326
      Filling And Emptying The Bucket (SJC - ISO Pattern)....327
      Leveling The Ground Using Float (SJC - ISO Pattern)....328
      Digging And Filling A Hole (SJC - ISO Pattern)....329
    TOWING THE LOADER....330
      Procedure....330
    LIFTING THE LOADER....330
      Single-Point Lift....330
      Four-Point Lift....331
    TRANSPORTING THE LOADER ON A TRAILER....332
      Loading And Unloading....332
      Fastening....332
  PREVENTIVE MAINTENANCE....334
    MAINTENANCE SAFETY....338
    SERVICE SCHEDULE....340
      Chart....340
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....341
      Inspecting The BICS (Engine STOPPED - Key ON)....341
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....341
      Inspecting The Seat Bar Sensor (Engine RUNNING)....341
      Inspecting The Traction Lock (Engine RUNNING)....341
      Inspecting The Lift Arm Bypass Control....341
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....341
    SEAT BAR RESTRAINT SYSTEM....342
      Description....342
      Inspecting....342
      Maintaining....342
    SEAT BELT....343
      Inspection And Maintenance....343
    LIFT ARM SUPPORT DEVICE....344
      Installing....344
      Removing....345
    BACK-UP ALARM SYSTEM....346
      Description....346
      Inspecting....346
      Adjusting Switch Position....347
    OPERATOR CAB....348
      Description....348
      Raising....348
      Lowering....349
      Cab Door Sensor....350
    REAR DOOR (TAILGATE)....351
      Opening And Closing....351
      Adjusting....351
    REAR GRILLE....352
      Removing....352
      Installing....352
    HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....353
      Cleaning And Maintenance....353
      Filters....353
      Evaporator / Heater Coil....354
      Condenser....355
      Air Conditioning Lubrication....355
      Troubleshooting....355
    AIR CLEANER SERVICE....355
      Replacing Filter Elements....355
    FUEL SYSTEM....357
      Fuel Specifications....357
      Biodiesel Blend Fuel....357
      Filling The Fuel Tank....358
      Fuel Filter....359
      Removing Air From The Fuel System....359
    ENGINE LUBRICATION SYSTEM....360
      Checking And Adding Engine Oil....360
      Engine Oil Chart....360
      Removing And Replacing Oil And Filter....361
    ENGINE COOLING SYSTEM....362
      Maintenance Platform....362
      Cleaning....362
      Checking Level....364
      Removing And Replacing Coolant....364
    ELECTRICAL SYSTEM....365
      Description....365
      Fuse And Relay Location / Identification....365
      Battery Maintenance....368
      Using A Booster Battery (Jump Starting)....369
      Removing And Installing Battery....370
    HYDRAULIC / HYDROSTATIC SYSTEM....371
      Checking And Adding Fluid....371
      Hydraulic / Hydrostatic Fluid Chart....371
      Removing And Replacing Hydraulic Fluid....372
      Removing And Replacing Hydraulic / Hydrostatic Filter....374
      Removing And Replacing Hydraulic Charge Filter....376
      Breather Cap....377
    SPARK ARRESTER MUFFLER....378
      Cleaning Procedure....378
    TRACK TENSION....379
      Description....379
      Checking (Solid-Mounted Undercarriage)....380
      Adjusting (Solid-Mounted Undercarriage)....381
      Checking (Roller Suspension Undercarriage)....382
      Adjusting (Roller Suspension Undercarriage)....383
    HYDROSTATIC DRIVE MOTOR....384
      Removing And Replacing Oil....384
    TRACK SPROCKET MAINTENANCE....384
      Tightening Procedure....384
    ALTERNATOR BELT....385
      Belt Adjustment....385
      Belt Replacement....385
    AIR CONDITIONING BELT....386
      Belt Adjustment....386
      Belt Replacement....386
    DRIVE BELT....387
      Belt Adjustment....387
      Stop Adjustment....387
      Belt Replacement....387
    LUBRICATING THE LOADER....389
      Lubrication Locations....389
    TRACK ROLLER AND IDLER LUBRICATION....391
      Procedure....391
    PIVOT PINS....391
      Inspection And Maintenance....391
    BOB-TACH (HAND LEVER)....392
      Inspection And Maintenance....392
    BOB-TACH (POWER)....393
      Inspection And Maintenance....393
    LOADER STORAGE AND RETURN TO SERVICE....394
      Storage....394
      Return To Service....394
  SYSTEM SETUP & ANALYSIS....396
    DIAGNOSTIC SERVICE CODES....398
      Viewing Service Codes....398
      Service Codes List....399
    CONTROL PANEL SETUP....404
      Right Panel Setup (Deluxe Instrumentation Panel)....404
    PASSWORD SETUP (KEYLESS START PANEL)....406
      Password Description....406
      Changing The Owner Password....406
      Password Lockout Feature....406
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....407
      Password Description....407
      Changing The Owner Password....407
      Changing The User Passwords....408
      Password Lockout Feature....408
    MAINTENANCE CLOCK....409
      Description....409
      Setup....409
      Reset....409
  MACHINE SIGN TRANSLATIONS....410
    MACHINE SIGN TRANSLATIONS....412
      Service Schedule (7167998)....412
      Warning (7167993)....415
      Warning (7169291)....415
      Danger (7167989)....415
      Danger (7167990)....415
      Danger (7167988)....416
      Warning (7168114)....416
      Warning (7167994)....417
      Warning (7168140)....418
      Warning (7168142)....418
      Warning (7168138)....419
      Warning (7167996)....420
      Warning (6737189)....420
      Warning (7184346)....421
      Danger (7170355)....421
      Lift Arm Support Device (6706558)....422
      Warning (7168024)....423
      Warning (7142141)....424
      Warning (7168019)....425
  SPECIFICATIONS....426
    (T630) LOADER SPECIFICATIONS....428
      Machine Dimensions....428
      Performance....429
      Engine....429
      Drive System....429
      Controls....430
      Hydraulic System....430
      Electrical System....431
      Capacities....431
      Tracks....431
      Ground Pressure....431
  WARRANTY....432
    WARRANTY....434
  ALPHABETICAL INDEX....436
6987164 (10-10) - T630 Compact Track Loader Service Manual....438
  MAINTENANCE SAFETY....440
  CONTENTS....442
  FOREWORD....444
    FOREWORD....446
    SAFETY INSTRUCTIONS....449
    FIRE PREVENTION....451
      Maintenance....451
      Operation....451
      Electrical....451
      Hydraulic System....451
      Fueling....451
      Starting....451
      Spark Arrestor Exhaust System....451
      Welding And Grinding....452
      Fire Extinguishers....452
    SERIAL NUMBER LOCATIONS....453
      Loader Serial Number....453
      Engine Serial Number....453
    DELIVERY REPORT....454
    LOADER IDENTIFICATION....455
  SAFETY & MAINTENANCE....456
    LIFTING AND BLOCKING THE LOADER....458
      Procedure....458
    LIFT ARM SUPPORT DEVICE....460
      Installing....460
      Removing....461
    OPERATOR CAB....462
      Description....462
      Raising....463
      Lowering....464
      Cab Door Sensor....465
      Special Applications Kit....465
      Special Applications Kit Inspection And Maintenance....465
    TRANSPORTING THE LOADER ON A TRAILER....466
      Loading And Unloading....466
      Fastening....466
    TOWING THE LOADER....468
      Procedure....468
    REMOTE START TOOL KIT-MEL1563....470
      Remote Start Tool - MEL1563....470
      Service Tool Harness Control - MEL1565....471
      Service Tool Harness Communicator - MEL1566....472
      Remote Start Procedure....472
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....476
      Description....476
      Remote Start Tool (Service Tool) - 7003030....477
      Loader Service Tool Harness - 6689747....478
      Computer Service Tool Harness - 6689746....479
      Remote Start Procedure....480
    SERVICE SCHEDULE....484
      Chart....484
    AIR CLEANER SERVICE....486
      Replacing Filter Elements....486
    ENGINE COOLING SYSTEM....488
      Maintenance Platform....488
      Cleaning....488
      Checking Level....490
      Removing And Replacing Coolant....490
    FUEL SYSTEM....492
      Fuel Specifications....492
      Biodiesel Blend Fuel....492
      Filling The Fuel Tank....493
      Fuel Filter....494
      Removing Air From The Fuel System....494
    ENGINE LUBRICATION SYSTEM....496
      Checking And Adding Engine Oil....496
      Engine Oil Chart....496
      Removing And Replacing Oil And Filter....497
    HYDRAULIC / HYDROSTATIC SYSTEM....498
      Checking And Adding Fluid....498
      Hydraulic / Hydrostatic Fluid Chart....498
      Removing And Replacing Hydraulic Fluid....499
      Removing And Replacing Hydraulic / Hydrostatic Filter....501
      Removing And Replacing Hydraulic Charge Filter....503
      Breather Cap....504
    BOB-TACH (HAND LEVER)....506
      Inspection And Maintenance....506
    BOB-TACH (POWER)....508
      Inspection And Maintenance....508
    LUBRICATING THE LOADER....510
      Lubrication Locations....510
    SPARK ARRESTOR MUFFLER....512
      Cleaning Procedure....512
    PIVOT PINS....514
      Inspection And Maintenance....514
    LOADER STORAGE AND RETURN TO SERVICE....516
      Storage....516
      Return To Service....516
    STOPPING THE ENGINE AND LEAVING THE LOADER....518
      Procedure....518
    EMERGENCY EXIT....520
      External Access....520
      Rear Window....520
      Front Door....520
    SEAT BELT....522
      Inspection And Maintenance....522
  HYDRAULIC SYSTEM....524
    HYDRAULIC / HYDROSTATIC SCHEMATICS....528
    HYDRAULIC SYSTEM INFORMATION....536
      Glossary Of Hydraulic / Hydrostatic Symbols....536
      Troubleshooting....540
    CYLINDER (LIFT)....542
      Testing....542
      Removal And Installation....543
      Parts Identification....545
      Disassembly....546
      Assembly....548
    CYLINDER (TILT)....550
      Testing....550
      Removal And Installation....551
      Base End Pivot Pin Removal And Installation....553
      Parts Identification....554
      Disassembly....555
      Assembly....557
    CYLINDER (BOB-TACH)....560
      Testing....560
      Removal And Installation....561
      Parts Identification....562
      Disassembly....563
      Assembly....564
    MAIN RELIEF VALVE....568
      Description....568
      Testing....569
      Adjusting....571
      Removal And Installation....572
    HYDRAULIC CONTROL VALVE (STANDARD)....574
      Description....574
      Removal And Installation....575
      Mount Bracket Removal And Installation....578
      Identification Chart....579
      Lift Load Check Valve Removal And Installation....580
      Load Check Valve Removal And Installation (Tilt & Auxiliary)....581
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....582
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....582
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....583
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....583
      Port Relief Valve Removal And Installation....584
      Plug Removal And Installation....585
      Rubber Boot Removal And Installation....586
      End Cap Block Removal And Installation....587
      Lift Spool And Detent Removal And Installation....588
      Tilt Spool Removal And Installation....598
      Auxiliary Spool Removal And Installation....600
      Auxiliary Solenoid Removal And Installation....602
      Solenoid Removal And Installation....603
      Lock Valve Removal And Installation....604
      Lift Arm Bypass Orifice Removal And Installation....606
      Main Relief Valve Removal And Installation....606
      Check Valve Removal And Installation....607
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....608
      Description....608
      Removal And Installation....608
      Actuator Removal And Installation (In Loader)....612
      Actuator Removal And Installation (Out Of Loader)....614
      Identification Chart....617
      Mount Bracket Removal And Installation....618
      Lift Load Check Valve Removal And Installation....618
      Load Check Valve Removal And Installation (Tilt & Auxiliary)....619
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....620
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....620
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....621
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....621
      Port Relief Valve Removal And Installation....622
      Plug Removal And Installation....623
      End Cap Block Removal And Installation....624
      Lift Spool Removal And Installation....624
      Tilt Spool Removal And Installation....629
      Auxiliary Spool Removal And Installation....631
      Auxiliary Solenoid Removal And Installation....633
      Solenoid Removal And Installation....634
      Lock Valve Removal And Installation....635
      Lift Arm Bypass Orifice Removal And Installation....636
      Main Relief Valve Removal And Installation....636
      Check Valve Removal And Installation....637
    LIFT ARM BYPASS CONTROL VALVE....638
      Description....638
      Testing....638
      Removal And Installation....639
      Bracket Removal And Installation....640
      Disassembly And Assembly....640
    HYDRAULIC PUMP....642
      Description....642
      Pump Test At Quick Couplers....642
      Direct Pump Test (Standard Section)....643
      Direct Pump Test (Charge Section)....645
      Removal And Installation....647
      Hydraulic Pump Startup....648
      Parts Identification....649
      Disassembly And Assembly....650
    HYDRAULIC PUMP (HIGH FLOW)....652
      Description....652
      Pump Test At Quick Couplers....652
      Direct Pump Test (Standard Section)....653
      Direct Pump Test (Charge Section)....654
      Direct Pump Test (High Flow Section)....656
      High Flow Relief Valve Adjustment....658
      High Flow Relief Valve Removal And Installation....659
      Solenoid Removal And Installation....660
      Removal And Installation....661
      Hydraulic Pump Startup....662
      Parts Identification....663
      Disassembly And Assembly....664
    HYDRAULIC / HYDROSTATIC FILTERS....666
      Description....666
      Housing Removal And Installation....666
    HYDRAULIC FLUID RESERVOIR....668
      Description....668
      Removal And Installation....668
      Hydraulic Fluid Screen....669
    OIL COOLER....670
      Description....670
      Removal And Installation....670
    BUCKET POSITION VALVE....672
      Description....672
      Solenoid Removal And Installation....672
      Solenoid Testing....673
      Removal And Installation....673
      Disassembly And Assembly....675
    REAR AUXILIARY DIVERTER VALVE....676
      Description....676
      Solenoid Testing....676
      Removal And Installation....677
      Disassembly And Assembly....678
    BOB-TACH (POWER) BLOCK....684
      Description....684
      Removal And Installation....684
      Disassembly And Assembly....686
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....690
      Description....690
      Removal And Installation....690
      Disassembly And Assembly....691
  HYDROSTATIC SYSTEM....694
    HYDROSTATIC SYSTEM INFORMATION....696
      Description....696
      Troubleshooting....697
    HYDROSTATIC DRIVE MOTOR....698
      Description....698
      Removing And Replacing Oil....698
      Removal And Installation....699
      Parts Identification....701
      Disassembly And Assembly....703
    CHARGE PRESSURE....716
      Description....716
      Testing....716
      Sender Removal And Installation....718
      Adjusting....719
    HYDROSTATIC PUMP....722
      Description....722
      Removal And Installation....723
      Hydrostatic Pump Startup....724
      Replenishing / High Pressure Relief Valve Removal And Installation....725
      Parts Identification (Left Half)....726
      Parts Identification (Right Half)....727
      Disassembly....728
      Assembly....735
    HYDROSTATIC PUMP (SJC)....742
      Description....742
      Hydraulic Controller Removal And Installation....743
      Removal And Installation....745
      Hydrostatic Pump Startup....747
      Parts Identification....748
      High Pressure Relief And Bypass Valve....749
      Charge Relief Valve....750
      Disassembly And Assembly....751
      Mechanical Neutral Adjustment....764
      Hydraulic Controller Neutral Adjustment....767
    DRIVE BELT....770
      Belt Adjustment....770
      Belt Replacement....770
      Stop Adjustment....772
      Tensioner Pulley Removal And Installation....773
      Tensioner Pulley Disassembly And Assembly....773
    DRAIN MANIFOLD....776
      Description....776
      Drain Manifold Removal And Installation....776
  DRIVE SYSTEM....778
    BRAKE....780
      Description....780
      Block Removal And Installation....780
      Block Disassembly And Assembly....781
    TRACK UNDERCARRIAGE COMPONENTS (SOLID- MOUNTED)....784
      Description....784
      Checking Tension....785
      Adjusting Tension....786
      Track Removal And Installation....787
      Idler (Front) Removal And Installation....789
      Track Tensioner Disassembly And Assembly....792
      Idler (Rear) Removal And Installation....794
      Roller Removal And Installation....794
      Sprocket Removal And Installation....795
      Track Housing Removal And Installation....796
    TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION)....798
      Description....798
      Checking Tension....799
      Adjusting Tension....800
      Track Removal And Installation....801
      Idler (Front) Removal And Installation....803
      Track Tensioner Disassembly And Assembly....806
      Idler (Rear) Removal And Installation....808
      Roller Removal And Installation....808
      Leaf Spring Removal And Installation....809
      Sprocket Removal And Installation....810
      Track Housing Removal And Installation....811
    TRACK MAINTENANCE....812
      Track Damage Identification....812
  MAINFRAME....824
    SEAT BAR....828
      Description....828
      Removal And Installation....828
      Disassembly And Assembly....829
      Compression Spring Disassembly And Assembly....830
    OPERATOR CAB....832
      Gas Spring Removal And Installation....832
      Gas Spring Bracket Disassembly And Assembly....833
      Removal And Installation....833
    OPERATOR SEAT (SUSPENSION)....836
      Removal And Installation....836
      Slide Rail Removal And Installation....836
      Seat Belt Removal And Installation....837
      Lower Cushion Removal....837
      Lower Cushion Installation....838
      Back Cushion Removal And Installation....838
      Shock Removal And Installation....839
      3-Point Seat Belt Removal And Installation....839
    BOB-TACH (HAND LEVER)....842
      Description....842
      Removal And Installation....842
      Lever And Wedge Disassembly And Assembly....844
      Pivot Pin Bushing And Seal Removal And Installation....846
    BOB-TACH (POWER)....848
      Description....848
      Removal And Installation....848
      Lever And Wedge Disassembly And Assembly....851
      Pivot Pin Bushing And Seal Removal And Installation....852
    LIFT ARMS....854
      Removal And Installation....854
    REAR GRILLE....856
      Removal And Installation....856
    REAR DOOR (TAILGATE)....858
      Removal And Installation....858
      Striker Removal And Installation....859
      Striker Disassembly And Assembly....859
      Striker (Adjusting)....859
      Latch Removal And Installation....860
    FUEL TANK....862
      Removal And Installation....862
      Fuel Level Sender Removal And Installation....864
      Fuel Fill Screen Removal And Installation....864
    CONTROL PEDALS AND LINKAGES....866
      Description....866
      Pedal Removal And Installation....866
      Linkage Removal And Installation....867
      Pedal (Adjusting)....868
      Floor Pan Removal And Installation....869
    CONTROL PEDALS AND LINKAGES (ACS)....870
      Description....870
      Pedal Removal And Installation....870
      Linkage Removal And Installation....871
      Pedal (Adjusting)....871
      Floor Pan Removal And Installation....872
    CONTROL PANEL....874
      Description....874
      Removal And Installation....875
      Disassembly And Assembly....876
      Linkage Removal And Installation....878
      Pintle Arm Disassembly And Assembly....882
      Linkage Neutral (Adjusting)....883
      Linkage Travel (Adjusting)....887
      Shock Removal And Installation....891
    CONTROL PANEL (SJC)....892
      Description....892
      Removal And Installation....892
    CONTROL HANDLE / LEVER....894
      Description....894
      Lever Removal And Installation....894
      Boot Removal And Installation....895
    CONTROL HANDLE / LEVER (ACS)....896
      Description....896
      Handle Sensor Removal And Installation....896
      Handle Removal And Installation....899
      Handle Disassembly And Assembly....900
      Lever Removal And Installation....900
      Boot Removal And Installation....901
    CONTROL HANDLE / LEVER (SJC)....902
      Description....902
      Joystick Testing....902
      Joystick Removal And Installation....903
    ACCESS PANEL (INSIDE)....904
      Removal And Installation (Left)....904
      Removal And Installation (Right)....904
    ACCESS PANEL (INSIDE) (SJC)....906
      Removal And Installation (Left)....906
      Removal And Installation (Right)....906
    WINDOW (REAR)....908
      Removal And Installation....908
      Disassembly And Assembly....908
    WINDOW (TOP)....910
      Removal And Installation....910
    WINDOW (SIDE)....912
      Removal And Installation....912
    CAB DOOR....914
      Description....914
      Removal And Installation....914
      Disassembly And Assembly....915
      Aligning....916
      Adjusting....917
      Checking Operation....917
    ARMREST....918
      Description....918
      Removal And Installation....919
      Disassembly And Assembly....920
    LEFT SIDE LOWER PANEL....922
      Removal And Installation....922
      Disassembly And Assembly....924
    RIGHT SIDE LOWER PANEL....926
      Removal And Installation....926
      Disassembly And Assembly....927
    HEADLINER....930
      Removal And Installation....930
  ELECTRICAL SYSTEM & ANALYSIS....932
    ELECTRICAL SCHEMATICS....936
    ELECTRICAL SYSTEM INFORMATION....964
      Glossary Of Electrical Symbols....964
      Standard Cab Harness Connectors....967
      Deluxe Cab Harness Connectors....968
      Mainframe Harness Connectors....969
      Description....970
      Troubleshooting....971
      Fuse And Relay Location / Identification....972
      Solenoid Testing....975
    BATTERY....976
      Removal And Installation....976
      Servicing....977
      Using A Booster Battery (Jump Starting)....978
    ALTERNATOR....980
      Belt Adjustment....980
      Belt Replacement....980
      Charging System Inspection....981
      Alternator Voltage Testing....982
      Low Voltage Testing....982
      High Voltage Testing....983
      Removal And Installation....984
      Parts Identification....985
    STARTER....986
      Testing....986
      Removal And Installation....986
      Parts Identification....987
    INSTRUMENT PANELS....988
      Left Panel....988
      Display Screen....990
      Right Panel (Standard Key Panel)....991
      Right Panel (Keyless Start Panel)....992
      Right Panel (Deluxe Instrumentation Panel)....993
      Left Switch Panel....995
      Right Switch Panel....995
      Left Panel Removal And Installation....996
      Right Panel (Standard Key Panel) Removal And Installation....996
      Right Panel (Keyless Start Panel) Removal And Installation....997
      Right Panel (Deluxe Instrumentation Panel) Removal And Installation....997
      Key Switch Disassembly And Assembly....998
      Alarm Disassembly And Assembly....998
      Left Switch Panel Removal And Installation....999
      Right Switch Panel Removal And Installation....999
    LIGHTS....1000
      Front Removal And Installation....1000
      Rear Removal And Installation....1001
      Cab Light Removal And Installation....1001
    BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)....1002
      Description....1002
      Connector Identification....1003
      Removal And Installation....1009
    BOBCAT CONTROLLER (ACS)....1010
      Description....1010
      Connector And Wire Identification....1011
      Removal And Installation....1012
    BOBCAT CONTROLLER (SJC) (DRIVE)....1014
      Description....1014
      Connector Identification....1015
      Removal And Installation....1017
    SPEED SENSORS (SJC)....1018
      Description....1018
      Testing....1018
      Removal And Installation....1019
    DIAGNOSTIC SERVICE CODES....1022
      Viewing Service Codes....1022
      Service Codes List....1023
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....1028
      Description....1028
      Inspecting The BICS (Engine STOPPED - Key ON)....1029
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....1029
      Inspecting The Seat Bar Sensor (Engine RUNNING)....1029
      Inspecting The Traction Lock (Engine RUNNING)....1029
      Inspecting The Lift Arm Bypass Control....1029
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....1029
      Troubleshooting....1030
    SEAT BAR SENSOR....1032
      Description....1032
      Troubleshooting....1032
      Testing....1033
      Removal And Installation....1034
      Bobcat Interlock Control System (BICS) Circuit Test....1035
    TRACTION LOCK....1038
      Description....1038
      Troubleshooting....1039
      Inspecting....1040
    CONTROL SYSTEM (ACS)....1042
      Description....1042
      Troubleshooting....1043
      Handle Sensor Connector Disassembly And Assembly....1044
      Switch Handle Removal....1045
      Switch Handle Installation....1047
      Actuator Connector Disassembly And Assembly....1050
      Handle Lock Solenoid Removal And Installation....1051
      Handle Lock Solenoid Disassembly And Assembly....1051
      Foot Sensor Removal And Installation....1052
      Foot Sensor Disassembly And Assembly....1053
      Foot Sensor Lock Solenoid Removal And Installation....1053
    ELECTRICAL / HYDRAULIC CONTROLS....1054
      Identification Chart....1054
      Description....1055
      Identification Chart ACD Group 0....1056
      Identification Chart ACD Group 1....1057
      Identification Chart ACD Group 2....1058
      Identification Chart ACD Group 3....1059
    ELECTRICAL / HYDRAULIC CONTROLS (ACS)....1060
      Identification Chart....1060
      Description....1061
      Identification Chart ACD Group 0....1062
      Identification Chart ACD Group 1....1063
      Identification Chart ACD Group 2....1064
      Identification Chart ACD Group 3....1065
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)....1066
      Identification Chart....1066
      Description....1067
      Identification Chart ACD Group 0....1068
      Identification Chart ACD Group 1....1069
      Identification Chart ACD Group 2....1070
      Identification Chart ACD Group 3....1071
    SERVICE PC (LAPTOP COMPUTER)....1072
      Connecting Remote Start Tool....1072
      Connecting Remote Start Tool (Service Tool)....1072
    CALIBRATION....1074
      Description....1074
      Actuator Testing....1074
      Lift And Tilt Calibration (SJC)....1077
      Hydrostatic Pump Calibration (SJC)....1079
      Lift And Tilt Calibration (ACS)....1084
    STEERING DRIFT COMPENSATION....1086
      Description....1086
      Operation....1086
    FLYWHEEL RPM SENSOR....1088
      Description....1088
      Adjustment....1089
    CONTROL PANEL SETUP....1090
      Right Panel Setup (Deluxe Instrumentation Panel)....1090
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....1092
      Password Description....1092
      Changing The Owner Password....1092
      Changing The User Passwords....1093
      Password Lockout Feature....1093
    PASSWORD SETUP (KEYLESS START PANEL)....1094
      Password Description....1094
      Changing The Owner Password....1094
      Password Lockout Feature....1094
    MAINTENANCE CLOCK....1096
      Description....1096
      Setup....1097
      Reset....1100
    BACK-UP ALARM SYSTEM....1102
      Description....1102
      Inspecting....1102
      Adjusting Switch Position....1103
      Troubleshooting (Standard And ACS)....1104
      Troubleshooting (Joystick)....1105
      Alarm Removal And Installation....1106
      Switch Removal And Installation....1106
    FRONT HORN....1108
      Removal And Installation....1108
  ENGINE SERVICE....1110
    ENGINE INFORMATION....1114
      Description....1114
      Specifications....1115
      Torque Values....1118
      Troubleshooting....1118
      Engine Removal And Installation....1120
      Engine Mount Replacement....1127
      Compression - Checking....1128
    ENGINE SPEED CONTROL....1130
      Removal And Installation....1130
      Disassembly And Assembly....1130
      Cable Removal And Installation....1131
    ENGINE SPEED CONTROL (SJC) S/N A7PU11431 AND BELOW....1132
      Removal And Installation....1132
      Disassembly And Assembly....1133
    ENGINE SPEED CONTROL (SJC) S/N A7PU11432 AND ABOVE....1136
      Removal And Installation....1136
      Disassembly And Assembly....1137
    MUFFLER....1140
      Removal And Installation....1140
    AIR CLEANER....1142
      Housing Removal And Installation....1142
      Housing Bracket Removal And Installation....1143
    ENGINE COOLING SYSTEM....1144
      Radiator Removal And Installation....1144
      Hydraulic Fan Description....1146
      Hydraulic Fan Disassembly And Assembly....1147
      Lower Fan Duct Removal And Installation....1148
      Blower Housing Removal And Installation....1148
      Hydraulic Fan Motor Assembly Removal And Installation....1149
      Fan Removal And Installation....1149
      Hydraulic Fan Motor Removal And Installation....1150
      Water Pump Removal And Installation....1151
      Water Pump Disassembly And Assembly....1151
      Thermostat Housing Removal And Installation....1152
      Thermostat - Checking....1153
    LUBRICATION SYSTEM....1154
      Oil Pan Removal And Installation....1154
      Oil Pump Removal And Installation....1154
      Relief Valve - Testing....1155
      Oil Pump Inspection....1155
      Oil Filter Cooler Removal And Installation....1156
      Engine Oil Pressure - Testing....1157
    FUEL SYSTEM....1158
      Fuel Shutoff Solenoid - Checking....1158
      Fuel Shutoff Solenoid Removal And Installation....1158
      Fuel Injection Pump - Checking....1159
      Fuel Injection Pump Assembly Removal And Installation....1160
      Governor Housing Disassembly And Assembly....1163
      Governor Disassembly And Assembly....1165
      Fuel Camshaft Removal And Installation....1167
      Fuel Injection Pump Removal And Installation....1169
      Fuel Injection Pump - Timing....1171
      Fuel Injector Removal And Installation....1173
      Fuel Injector Nozzle Pressure - Checking....1174
      Nozzle Spray Condition....1175
      Valve Seat Tightness....1175
    CYLINDER HEAD....1176
      Glow Plugs - Testing....1176
      Glow Plugs Removal And Installation....1176
      Valve Clearance Adjustment....1177
      Valve Timing - Checking....1178
      Cylinder Head Removal And Installation....1179
      Cylinder Head Disassembly And Assembly....1182
      Cylinder Head - Servicing....1182
      Cylinder Head Top Clearance....1183
      Valve Guide - Checking....1183
      Valve Guide Removal And Installation....1184
      Reconditioning The Valve And Valve Seat....1184
      Valve Spring....1186
      Valve Tappets....1187
      Rocker Arm And Shaft - Checking....1188
      Bridge Arm And Bridge Arm Shaft - Checking....1188
      Bridge Arm Shaft - Removal And Installation....1189
      Push Rod Alignment - Checking....1190
    CRANKSHAFT AND PISTONS....1192
      Piston And Connecting Rod Removal And Installation....1192
      Piston And Connecting Rod - Servicing....1193
      Cylinder Bore - Checking....1196
      Connecting Rod Alignment....1197
      Crankshaft Gear Removal And Installation....1197
      Crankshaft And Bearings Removal And Installation....1198
      Crankshaft And Bearings - Servicing....1200
    CAMSHAFT AND TIMING GEARS....1204
      Timing Gearcase Cover Removal....1204
      Timing Gearcase Cover Installation....1205
      Timing Gears Backlash - Checking....1208
      Idler Gear And Camshaft Removal And Installation....1208
      Camshaft - Servicing....1209
      Idler Gear And Shaft - Servicing....1210
    TURBOCHARGER....1212
      Description....1212
      Testing....1212
      Removal And Installation....1213
    FLYWHEEL AND HOUSING....1216
      Flywheel Removal And Installation....1216
      Ring Gear Removal And Installation....1218
      Housing Removal And Installation....1218
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM....1220
      Description....1220
      Testing....1221
      Removal And Installation....1224
      Disassembly And Assembly....1225
  HEATING, VENTILATION, AIR CONDITIONING....1226
    AIR CONDITIONING SYSTEM FLOW....1229
      Description....1229
      Chart....1230
      Components....1231
      Safety Equipment....1234
    REGULAR MAINTENANCE....1236
      Filters....1236
      Compressor Drive Belt Adjustment....1237
      Compressor Drive Belt Replacement....1237
      Condenser....1237
      Air Conditioning Lubrication....1237
      Air Conditioning Service Chart....1238
      Evaporator / Heater Coil....1239
    TROUBLESHOOTING....1240
      Blower Motor Does Not Operate....1240
      Blower Motor Operates Normally, But Air Flow Is Insufficient....1240
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....1240
      The Compressor Does Not Operate At All, Or Operates Improperly....1240
      Gauge Pressure Related Troubleshooting....1241
      Troubleshooting Tree....1243
      Temperature / Pressure Chart....1247
      Poor A/C Performance....1249
      HVAC Repair And Leaks....1250
      Electrical System....1251
      Engine Coolant Bypassing The Heater Valve....1257
      Heater Valve Not Opening Or Closing....1258
    SYSTEM CHARGING AND RECLAMATION....1260
      Refrigerant Identification....1260
      Reclamation And Charging With Recovery / Charging Unit....1261
    COMPRESSOR....1264
      Removal And Installation....1264
      Oil....1265
      Oil Check....1266
    CONDENSER....1268
      Removal And Installation....1268
    RECEIVER / DRIER....1270
      Receiver / Drier Removal And Installation....1270
      Pressure Relief Valve Removal And Installation....1271
      Pressure Switch Removal And Installation....1272
      Schraeder Valve Removal And Installation....1273
    EVAPORATOR / HEATER UNIT....1274
      Removal And Installation....1274
    THERMOSTAT....1276
      Description....1276
      Removal And Installation....1277
    EXPANSION VALVE....1278
      Removal And Installation....1278
    EVAPORATOR COIL....1280
      Removal And Installation....1280
    HEATER COIL....1282
      Removal And Installation....1282
    BLOWER FAN....1284
      Removal And Installation....1284
      Disassembly And Assembly....1284
    HEATER VALVE....1288
      Removal And Installation....1288
  SPECIFICATIONS....1290
    (T630) LOADER SPECIFICATIONS....1292
      Machine Dimensions....1292
      Performance....1293
      Engine....1293
      Drive System....1293
      Controls....1294
      Hydraulic System....1294
      Electrical System....1295
      Capacities....1295
      Tracks....1295
      Ground Pressure....1295
    TORQUE SPECIFICATIONS FOR BOLTS....1296
      Torque For General SAE Bolts....1296
      Torque For General Metric Bolts....1297
    HYDRAULIC CONNECTION SPECIFICATIONS....1298
      Straight Thread O-ring Fitting....1298
      Flare Fitting....1299
      Tubelines And Hoses....1299
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....1300
      Specifications....1300
    CONVERSIONS....1302
      Decimal And Millimeter Equivalent Chart....1302
      U.S. To Metric Conversion Chart....1302
  ALPHABETICAL INDEX....1304
  SERVICE MANUAL REVISION....1308
    Revision No: T630 - 2....1308
    Revision No: T630 - 2....1310
    Revision No: T630 - 3....1312
    Revision No: T630 - 4....1314
    Revision No: T630 - 5....1316
    Revision No: T630 - 6....1318
    Revision No: T630 - 7....1320
6987164 (12-13) - T630 Compact Track Loader Service Manual....1322
  MAINTENANCE SAFETY....1324
  CONTENTS....1326
  FOREWORD....1328
    FOREWORD....1330
    SAFETY INSTRUCTIONS....1332
    FIRE PREVENTION....1334
      Maintenance....1334
      Operation....1334
      Electrical....1334
      Hydraulic System....1334
      Fueling....1334
      Starting....1334
      Spark Arrester Exhaust System....1334
      Welding And Grinding....1335
      Fire Extinguishers....1335
    SERIAL NUMBER LOCATIONS....1336
      Loader Serial Number....1336
      Engine Serial Number....1336
    DELIVERY REPORT....1337
    LOADER IDENTIFICATION....1338
  SAFETY & MAINTENANCE....1340
    LIFTING AND BLOCKING THE LOADER....1344
      Procedure....1344
    LIFT ARM SUPPORT DEVICE....1346
      Installing....1346
      Removing....1347
    OPERATOR CAB....1348
      Description....1348
      Raising....1349
      Lowering....1350
      Cab Door Sensor....1351
      Special Applications Kit....1352
      Special Applications Kit Inspection And Maintenance....1352
      Forestry Door And Window Kit....1353
      Forestry Door And Window Kit Inspection And Maintenance....1353
    TRANSPORTING THE LOADER ON A TRAILER....1354
      Loading And Unloading....1354
      Fastening....1354
    TOWING THE LOADER....1356
      Procedure....1356
    REMOTE START TOOL KIT- MEL1563....1358
      Remote Start Tool - MEL1563....1358
      Service Tool Harness Communicator - MEL1566....1360
      Remote Start Procedure....1360
    REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....1364
      Description....1364
      Remote Start Tool (Service Tool) - 7022042....1365
      Loader Service Tool Harness - 6689747....1366
      Computer Service Tool Harness - 6689746....1367
      Remote Start Procedure....1368
    SERVICE SCHEDULE....1372
      Chart....1372
    AIR CLEANER SERVICE....1374
      Replacing Filter Elements....1374
    ENGINE COOLING SYSTEM....1376
      Maintenance Platform....1376
      Cleaning....1376
      Checking Level....1378
      Removing And Replacing Coolant....1378
    FUEL SYSTEM....1380
      Fuel Specifications....1380
      Biodiesel Blend Fuel....1380
      Filling The Fuel Tank....1381
      Fuel Filter....1382
      Removing Air From The Fuel System....1382
    ENGINE LUBRICATION SYSTEM....1384
      Checking And Adding Engine Oil....1384
      Engine Oil Chart....1384
      Removing And Replacing Oil And Filter....1385
    HYDRAULIC / HYDROSTATIC SYSTEM....1388
      Checking And Adding Fluid....1388
      Hydraulic / Hydrostatic Fluid Chart....1388
      Removing And Replacing Hydraulic Fluid....1389
      Removing And Replacing Hydraulic / Hydrostatic Filter....1391
      Removing And Replacing Hydraulic Charge Filter....1393
      Breather Cap....1394
    BOB-TACH (HAND LEVER)....1396
      Inspection And Maintenance....1396
    BOB-TACH (POWER)....1398
      Inspection And Maintenance....1398
    LUBRICATING THE LOADER....1400
      Lubrication Locations....1400
    SPARK ARRESTER MUFFLER....1404
      Cleaning Procedure....1404
    PIVOT PINS....1406
      Inspection And Maintenance....1406
    LOADER STORAGE AND RETURN TO SERVICE....1408
      Storage....1408
      Return To Service....1408
    STOPPING THE ENGINE AND LEAVING THE LOADER....1410
      Procedure....1410
    EMERGENCY EXIT....1412
      Rear Window Identification....1412
      Rear Window Removal (Latches)....1412
      Rear Window Removal (Rubber Cord)....1413
      External Access (Rear Window With Latches)....1414
      External Access (Rear Window With Rubber Cord)....1414
      Front Door....1414
    SEAT BELT....1416
      Inspection And Maintenance....1416
  HYDRAULIC SYSTEM....1418
    HYDRAULIC / HYDROSTATIC SCHEMATICS....1424
    HYDRAULIC SYSTEM INFORMATION....1436
      Glossary Of Hydraulic / Hydrostatic Symbols....1436
      Troubleshooting....1440
    CYLINDER (LIFT)....1442
      Testing....1442
      Removal And Installation....1443
      Parts Identification....1445
      Disassembly....1446
      Assembly....1448
    CYLINDER (TILT)....1452
      Testing....1452
      Removal And Installation....1453
      Base End Pivot Pin Removal And Installation....1455
      Parts Identification (Early Models)....1456
      Parts Identification (Later Models)....1457
      Disassembly....1458
      Assembly....1461
    CYLINDER (BOB-TACH)....1464
      Testing....1464
      Removal And Installation....1465
      Parts Identification....1466
      Disassembly....1467
      Assembly....1468
    MAIN RELIEF VALVE (EARLY MODELS)....1472
      Description....1472
      Testing....1473
      Adjusting....1475
      Removal And Installation....1476
    MAIN RELIEF VALVE (LATER MODELS)....1478
      Description....1478
      Testing....1479
      Main Relief Valve Adjustment....1481
      Main Relief Valve Removal And Installation....1481
      Auxiliary Relief Valve Adjustment....1482
      Auxiliary Relief Valve Removal And Installation....1483
    HYDRAULIC CONTROL VALVE (STANDARD) (EARLY MODELS)....1484
      Description....1484
      Removal And Installation....1485
      Mount Bracket Removal And Installation....1488
      Identification Chart....1489
      Lift Load Check Valve Removal And Installation....1490
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....1491
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....1492
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....1492
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....1493
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....1493
      Port Relief Valve Removal And Installation....1494
      Plug Removal And Installation....1495
      Rubber Boot Removal And Installation....1496
      End Cap Block Removal And Installation....1497
      Lift Spool And Detent Removal And Installation....1498
      Tilt Spool Removal And Installation....1508
      Auxiliary Spool Removal And Installation....1510
      Auxiliary Solenoid Removal And Installation....1512
      Solenoid Removal And Installation....1513
      Lock Valve Removal And Installation....1514
      Lift Arm Bypass Orifice Removal And Installation....1516
      Main Relief Valve Removal And Installation....1516
      Check Valve Removal And Installation....1517
    HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS)....1518
      Description....1518
      Removal And Installation....1519
      Mount Bracket Removal And Installation....1523
      Identification Chart....1524
      Lift Load Check Valve Removal And Installation....1525
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....1526
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....1527
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....1527
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....1528
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....1528
      Port Relief Valve Removal And Installation....1529
      Plug Removal And Installation....1531
      Rubber Boot Removal And Installation....1532
      End Cap Block Removal And Installation....1532
      Lift Spool And Detent Removal And Installation....1533
      Tilt Spool Removal And Installation....1541
      Auxiliary Spool Removal And Installation....1543
      Auxiliary Solenoid Removal And Installation....1544
      Solenoid Removal And Installation....1545
      Lock Valve Removal And Installation....1546
      Lift Arm Bypass Orifice Removal And Installation....1548
      Main Relief Valve Removal And Installation....1548
      Auxiliary Relief Valve Removal And Installation....1549
      Check Valve Removal And Installation....1549
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLY MODELS)....1552
      Description....1552
      Removal And Installation....1552
      Actuator Removal And Installation (In Loader)....1556
      Actuator Removal And Installation (Out Of Loader)....1558
      Identification Chart....1561
      Mount Bracket Removal And Installation....1562
      Lift Load Check Valve Removal And Installation....1562
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....1563
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....1564
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....1564
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....1565
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....1565
      Port Relief Valve Removal And Installation....1566
      Plug Removal And Installation....1567
      End Cap Block Removal And Installation....1568
      Lift Spool Removal And Installation....1568
      Tilt Spool Removal And Installation....1573
      Auxiliary Spool Removal And Installation....1575
      Auxiliary Solenoid Removal And Installation....1577
      Solenoid Removal And Installation....1578
      Lock Valve Removal And Installation....1579
      Lift Arm Bypass Orifice Removal And Installation....1580
      Main Relief Valve Removal And Installation....1580
      Check Valve Removal And Installation....1581
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS)....1582
      Description....1582
      Removal And Installation....1582
      Actuator Removal And Installation (In Loader)....1587
      Actuator Removal And Installation (Out Of Loader)....1588
      Identification Chart....1591
      Mount Bracket Removal And Installation....1592
      Lift Load Check Valve Removal And Installation....1592
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....1593
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....1594
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....1594
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....1595
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....1595
      Port Relief Valve Removal And Installation....1596
      Plug Removal And Installation....1598
      End Cap Block Removal And Installation....1599
      Lift Spool Removal And Installation....1599
      Lift Spool Disassembly And Assembly....1601
      Tilt Spool Removal And Installation....1602
      Auxiliary Spool Removal And Installation....1604
      Auxiliary Solenoid Removal And Installation....1605
      Solenoid Removal And Installation....1606
      Lock Valve Removal And Installation....1607
      Lift Arm Bypass Orifice Removal And Installation....1609
      Main Relief Valve Removal And Installation....1609
      Auxiliary Relief Valve Removal And Installation....1610
      Check Valve Removal And Installation....1610
    LIFT ARM BYPASS CONTROL VALVE....1612
      Description....1612
      Testing....1612
      Removal And Installation....1613
      Bracket Removal And Installation....1614
      Disassembly And Assembly....1614
    HYDRAULIC PUMP....1616
      Description....1616
      Pump Test At Quick Couplers....1616
      Direct Pump Test (Standard Section)....1617
      Direct Pump Test (Charge Section)....1619
      Removal And Installation....1621
      Hydraulic Pump Startup....1623
      Parts Identification....1624
      Disassembly And Assembly....1625
    HYDRAULIC PUMP (HIGH FLOW)....1626
      Description....1626
      Pump Test At Quick Couplers....1626
      Direct Pump Test (Standard Section)....1627
      Direct Pump Test (Charge Section)....1628
      Direct Pump Test (High Flow Section)....1630
      High Flow Relief Valve Adjustment....1632
      High Flow Relief Valve Removal And Installation....1633
      Solenoid Removal And Installation....1634
      Removal And Installation....1635
      Hydraulic Pump Startup....1637
      Parts Identification....1638
      Disassembly And Assembly....1639
    HYDRAULIC / HYDROSTATIC FILTERS....1640
      Description....1640
      Housing Removal And Installation....1640
    HYDRAULIC FLUID RESERVOIR....1642
      Description....1642
      Removal And Installation....1642
      Hydraulic Fluid Screen....1643
    OIL COOLER....1644
      Description....1644
      Removal And Installation....1644
    BUCKET POSITION VALVE....1646
      Description....1646
      Solenoid Removal And Installation....1646
      Solenoid Testing....1647
      Removal And Installation....1647
      Disassembly And Assembly....1649
    REAR AUXILIARY DIVERTER VALVE....1650
      Description....1650
      Solenoid Testing....1650
      Removal And Installation....1651
      Disassembly And Assembly....1652
    BOB-TACH (POWER) BLOCK....1658
      Description....1658
      Removal And Installation....1658
      Disassembly And Assembly (Early Models)....1660
      Disassembly And Assembly (Later Models)....1664
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....1674
      Description....1674
      Removal And Installation....1674
      Disassembly And Assembly....1674
  HYDROSTATIC SYSTEM....1676
    HYDROSTATIC SYSTEM INFORMATION....1678
      Description....1678
      Troubleshooting....1679
    HYDROSTATIC DRIVE MOTOR....1680
      Description....1680
      Removing And Replacing Oil....1680
      Removal And Installation....1681
      Parts Identification....1683
      Disassembly And Assembly....1685
    HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N a7pu11001 - 13049)....1698
      Description....1698
      Removing And Replacing Oil....1698
      Removal And Installation....1699
      Parts Identification....1701
      Disassembly And Assembly....1703
    HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A7PU13050 & ABOVE)....1716
      Description....1716
      Removing And Replacing Oil....1716
      Removal And Installation....1717
      Parts Identification....1719
      Disassembly And Assembly....1721
    CHARGE PRESSURE....1734
      Description....1734
      Testing....1734
      Sender Removal And Installation....1736
      Adjusting....1737
    HYDROSTATIC PUMP....1740
      Description....1740
      Removal And Installation....1741
      Hydrostatic Pump Startup....1742
      Replenishing / High Pressure Relief Valve Removal And Installation....1743
      Parts Identification (Left Half)....1744
      Parts Identification (Right Half)....1745
      Disassembly....1746
      Assembly....1753
    32HYDROSTATIC PUMP (SJC)....1760
      Description....1760
      Hydraulic Controller Removal And Installation....1761
      Removal And Installation....1764
      Hydrostatic Pump Startup....1766
      Parts Identification....1767
      High Pressure Relief And Bypass Valve....1768
      Charge Relief Valve....1769
      Disassembly And Assembly....1770
      Mechanical Neutral Adjustment....1784
      Hydraulic Controller Neutral Adjustment....1787
    DRIVE BELT....1790
      Belt Adjustment....1790
      Stop Adjustment....1790
      Belt Replacement....1790
      Tensioner Pulley Removal And Installation....1792
      Tensioner Pulley Disassembly And Assembly....1792
    TWO-SPEED / BRAKE VALVE (S/N A7PU11001 - 13049)....1794
      Description....1794
      Valve Block Removal And Installation....1795
      Valve Block Disassembly And Assembly....1797
    TWO-SPEED / BRAKE VALVE (S/N A7PU13050 & ABOVE)....1800
      Description....1800
      Valve Block Removal And Installation....1801
      Valve Block Disassembly And Assembly....1803
    DRAIN MANIFOLD....1806
      Description....1806
      Drain Manifold Removal And Installation....1806
  DRIVE SYSTEM....1808
    BRAKE....1810
      Description....1810
      Block Removal And Installation....1810
      Block Disassembly And Assembly....1811
    BRAKE (TWO-SPEED)....1814
      Description....1814
    TRACK UNDERCARRIAGE COMPONENTS (SOLID- MOUNTED)....1816
      Description....1816
      Checking Tension....1817
      Adjusting Tension....1818
      Track Removal And Installation....1819
      Idler (Front) Removal And Installation....1821
      Track Tensioner Disassembly And Assembly....1824
      Idler (Rear) Removal And Installation....1826
      Roller Removal And Installation....1826
      Sprocket Removal And Installation (Single Speed)....1827
      Sprocket Removal And Installation (Two-Speed)....1827
      Track Housing Removal And Installation....1828
    TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION)....1830
      Description....1830
      Checking Tension....1831
      Adjusting Tension....1832
      Track Removal And Installation....1833
      Idler (Front) Removal And Installation....1835
      Track Tensioner Disassembly And Assembly....1838
      Idler (Rear) Removal And Installation....1840
      Roller Removal And Installation....1840
      Leaf Spring Removal And Installation....1841
      Sprocket Removal And Installation (Single Speed)....1842
      Sprocket Removal And Installation (Two Speed)....1842
      Track Housing Removal And Installation....1843
    TRACK MAINTENANCE....1844
      Track Damage Identification....1844
  MAINFRAME....1856
    SEAT BAR....1860
      Description....1860
      Removal And Installation....1860
      Disassembly And Assembly....1861
      Compression Spring Disassembly And Assembly....1862
    OPERATOR CAB....1864
      Gas Spring Removal And Installation....1864
      Gas Spring Bracket Disassembly And Assembly....1865
      Removal And Installation....1865
    OPERATOR SEAT (SUSPENSION)....1868
      Removal And Installation....1868
      Slide Rail Removal And Installation....1868
      Seat Belt Removal And Installation....1869
      Lower Cushion Removal....1869
      Lower Cushion Installation....1870
      Back Cushion Removal And Installation....1870
      Shock Removal And Installation....1871
      3-Point Seat Belt Removal And Installation....1871
    BOB-TACH (HAND LEVER)....1874
      Description....1874
      Removal And Installation....1874
      Lever And Wedge Disassembly And Assembly....1876
      Pivot Pin Bushing And Seal Removal And Installation....1878
    BOB-TACH (POWER)....1880
      Description....1880
      Removal And Installation....1880
      Lever And Wedge Disassembly And Assembly....1883
      Pivot Pin Bushing And Seal Removal And Installation....1884
    LIFT ARMS....1886
      Removal And Installation....1886
    REAR GRILLE....1888
      Identification....1888
      Lockable Handle Rear Grille....1889
      Clamping Knob Rear Grille....1890
      Slide In Rear Grille....1891
    REAR DOOR (TAILGATE)....1894
      Removal And Installation....1894
      Striker Removal And Installation....1895
      Striker Disassembly And Assembly....1895
      Striker (Adjusting)....1895
      Latch Removal And Installation (Early Models)....1896
      Latch Removal And Installation (Later Models)....1897
    FUEL TANK....1898
      Removal And Installation....1898
      Fuel Level Sender Removal And Installation....1900
      Fuel Fill Screen Removal And Installation....1900
    CONTROL PEDALS AND LINKAGES....1902
      Description....1902
      Pedal Removal And Installation....1902
      Linkage Removal And Installation....1903
      Pedal (Adjusting)....1904
      Floor Pan Removal And Installation....1905
    CONTROL PEDALS AND LINKAGES (ACS)....1906
      Description....1906
      Pedal Removal And Installation....1906
      Linkage Removal And Installation....1907
      Pedal (Adjusting)....1907
      Floor Pan Removal And Installation....1908
    CONTROL PANEL....1910
      Description....1910
      Removal And Installation....1911
      Disassembly And Assembly....1912
      Linkage Removal And Installation....1914
      Pintle Arm Disassembly And Assembly....1918
      Linkage Neutral (Adjusting)....1919
      Linkage Travel (Adjusting)....1923
      Shock Removal And Installation....1927
    CONTROL PANEL (SJC)....1928
      Description....1928
      Removal And Installation....1928
    CONTROL HANDLE / LEVER....1930
      Description....1930
      Lever Removal And Installation....1930
      Boot Removal And Installation....1931
    CONTROL HANDLE / LEVER (ACS)....1932
      Description....1932
      Handle Sensor Removal And Installation....1932
      Handle Removal And Installation....1935
      Handle Disassembly And Assembly....1936
      Lever Removal And Installation....1936
      Boot Removal And Installation....1937
    CONTROL HANDLE / LEVER (SJC)....1938
      Description....1938
      Joystick Testing....1938
      Joystick Removal And Installation....1939
    ACCESS PANEL (INSIDE)....1940
      Removal And Installation (Left)....1940
      Removal And Installation (Right)....1940
    ACCESS PANEL (INSIDE) (SJC)....1942
      Removal And Installation (Left)....1942
      Removal And Installation (Right)....1942
    WINDOW (REAR)....1944
      Removal And Installation....1944
      Disassembly And Assembly....1944
    WINDOW (TOP)....1946
      Removal And Installation....1946
    WINDOW (SIDE)....1948
      Removal And Installation....1948
    CAB DOOR....1950
      Description....1950
      Removal And Installation....1950
      Disassembly And Assembly....1951
      Aligning....1952
      Adjusting....1953
      Checking Operation....1953
    ARMREST....1954
      Description....1954
      Removal And Installation....1955
      Disassembly And Assembly....1956
    LEFT SIDE LOWER PANEL....1960
      Removal And Installation....1960
      Disassembly And Assembly....1962
    RIGHT SIDE LOWER PANEL....1964
      Removal And Installation....1964
      Disassembly And Assembly....1965
    HEADLINER....1968
      Removal And Installation....1968
  ELECTRICAL SYSTEM & ANALYSIS....1970
    ELECTRICAL SCHEMATICS....1976
    ELECTRICAL SYSTEM INFORMATION....2036
      Glossary Of Electrical Symbols....2036
      Standard Cab Harness Connectors....2039
      Deluxe Cab Harness Connectors....2040
      Mainframe Harness Connectors....2041
      Description....2042
      Troubleshooting....2043
      Fuse And Relay Location / Identification....2044
      Solenoid Testing....2047
    BATTERY....2048
      Removal And Installation....2048
      Servicing....2049
      Using A Booster Battery (Jump Starting)....2050
    ALTERNATOR....2052
      Belt Adjustment....2052
      Belt Replacement....2052
      Charging System Inspection....2054
      Alternator Voltage Testing....2055
      Low Voltage Testing....2055
      High Voltage Testing....2056
      Removal And Installation....2057
      Parts Identification....2059
    STARTER....2060
      Testing....2060
      Removal And Installation....2060
      Parts Identification....2061
    INSTRUMENT PANELS....2062
      Left Panel (Early Models)....2062
      Left Panel (Later Models)....2064
      Display Screen....2066
      Right Panel (Standard Key Panel)....2067
      Right Panel (Keyless Start Panel)....2068
      Right Panel (Deluxe Instrumentation Panel)....2069
      Left Switch Panel....2071
      Right Switch Panel....2071
      Left Side Lower Panel....2072
      Right Side Lower Panel....2072
      Left Panel Removal And Installation....2073
      Right Panel (Standard Key Panel) Removal And Installation....2073
      Right Panel (Keyless Start Panel) Removal And Installation....2074
      Right Panel (Deluxe Instrumentation Panel) Removal And Installation....2074
      Key Switch Disassembly And Assembly....2075
      Alarm Disassembly And Assembly....2075
      Left Switch Panel Removal And Installation....2076
      Right Switch Panel Removal And Installation....2076
    LIGHTS....2078
      Front Removal And Installation....2078
      Rear Removal And Installation....2079
      Cab Light Removal And Installation....2079
    BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)....2080
      Description....2080
      Connector Identification....2081
      Removal And Installation....2087
    BOBCAT CONTROLLER (ACS)....2090
      Description....2090
      Connector And Wire Identification....2091
      Removal And Installation....2092
    BOBCAT CONTROLLER (SJC) (DRIVE)....2094
      Description....2094
      Connector Identification....2095
      Removal And Installation....2097
    SPEED SENSORS (SJC)....2098
      Description....2098
      Testing....2098
      Removal And Installation....2099
    DIAGNOSTIC SERVICE CODES....2102
      Viewing Service Codes....2102
      Service Codes List....2103
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....2108
      Description....2108
      Inspecting The BICS (Engine STOPPED - Key ON)....2109
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....2109
      Inspecting The Seat Bar Sensor (Engine RUNNING)....2109
      Inspecting The Traction Lock (Engine RUNNING)....2109
      Inspecting The Lift Arm Bypass Control....2109
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....2109
      Troubleshooting....2110
    SEAT BAR SENSOR....2112
      Description....2112
      Troubleshooting....2112
      Testing....2113
      Removal And Installation....2114
      Bobcat Interlock Control System (BICS) Circuit Test....2117
    TRACTION LOCK....2120
      Description....2120
      Troubleshooting....2121
      Inspecting....2122
    CONTROL SYSTEM (ACS)....2124
      Description....2124
      Troubleshooting....2125
      Handle Sensor Connector Disassembly And Assembly....2126
      Switch Handle Removal....2127
      Switch Handle Installation....2129
      Actuator Connector Disassembly And Assembly....2132
      Handle Lock Solenoid Removal And Installation....2133
      Handle Lock Solenoid Disassembly And Assembly....2133
      Foot Sensor Removal And Installation....2134
      Foot Sensor Disassembly And Assembly....2135
      Foot Sensor Lock Solenoid Removal And Installation....2135
    ELECTRICAL / HYDRAULIC CONTROLS....2136
      Identification Chart....2136
      Description....2137
      Identification Chart ACD Group 0....2138
      Identification Chart ACD Group 1....2139
      Identification Chart ACD Group 2....2140
      Identification Chart ACD Group 3....2141
    ELECTRICAL / HYDRAULIC CONTROLS (ACS)....2142
      Identification Chart....2142
      Description....2143
      Identification Chart ACD Group 0....2144
      Identification Chart ACD Group 1....2145
      Identification Chart ACD Group 2....2146
      Identification Chart ACD Group 3....2147
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)....2148
      Identification Chart....2148
      Description....2149
      Identification Chart ACD Group 0....2150
      Identification Chart ACD Group 1....2151
      Identification Chart ACD Group 2....2152
      Identification Chart ACD Group 3....2153
    SERVICE PC (LAPTOP COMPUTER)....2154
      Connecting Remote Start Tool....2154
      Connecting Remote Start Tool (Service Tool)....2154
    CALIBRATION....2156
      Description....2156
      Actuator Testing....2156
      Lift And Tilt Calibration (SJC)....2159
      Hydrostatic Pump Calibration (SJC)....2161
      Lift And Tilt Calibration (ACS)....2166
    STEERING DRIFT COMPENSATION....2168
      Description....2168
      Operation....2168
    FLYWHEEL RPM SENSOR....2170
      Description....2170
      Removal And Installation....2171
    CONTROL PANEL SETUP....2172
      Right Panel Setup (Deluxe Instrumentation Panel)....2172
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....2176
      Password Description....2176
      Changing The Owner Password....2176
      Changing The User Passwords....2177
      Password Lockout Feature....2177
    PASSWORD SETUP (KEYLESS START PANEL)....2178
      Password Description....2178
      Changing The Owner Password....2178
      Password Lockout Feature....2178
    MAINTENANCE CLOCK....2180
      Description....2180
      Setup....2181
      Reset....2184
    BACK-UP ALARM SYSTEM....2186
      Description....2186
      Inspecting....2186
      Adjusting Switch Position....2187
      Troubleshooting (Standard And ACS)....2188
      Troubleshooting (Joystick)....2189
      Alarm Removal And Installation....2190
      Switch Removal And Installation....2190
    FRONT HORN....2192
      Removal And Installation....2192
      Troubleshooting....2193
      Troubleshooting (Joystick)....2194
  ENGINE SERVICE....2196
    ENGINE INFORMATION....2200
      Description....2200
      Specifications....2201
      Torque Values....2204
      Troubleshooting....2204
      Engine Removal And Installation....2206
      Engine Mount Replacement....2213
      Compression - Testing....2214
    ENGINE SPEED CONTROL....2218
      Removal And Installation....2218
      Disassembly And Assembly....2218
      Cable Removal And Installation....2219
    ENGINE SPEED CONTROL (SJC) (S/N A7PU11001 - 11431)....2220
      Removal And Installation....2220
      Disassembly And Assembly....2221
    ENGINE SPEED CONTROL (SJC) (S/N A7PU11432 & aBOVE)....2224
      Removal And Installation....2224
      Disassembly And Assembly....2225
    MUFFLER....2228
      Removal And Installation....2228
    AIR CLEANER....2230
      Housing Removal And Installation....2230
      Housing Bracket Removal And Installation....2231
    ENGINE COOLING SYSTEM (EARLY MODELS)....2232
      Radiator Removal And Installation....2232
      Hydraulic Fan Description....2234
      Fan Duct Removal And Installation....2235
      Hydraulic Fan Motor Assembly Removal And Installation....2235
      Hydraulic Fan Motor Removal And Installation....2236
      Hydraulic Fan Motor Disassembly And Assembly....2237
      Blower Housing Removal And Installation....2239
      Water Pump Removal And Installation....2240
      Water Pump Disassembly And Assembly....2240
      Thermostat Housing Removal And Installation....2241
      Thermostat - Testing....2242
    ENGINE COOLING SYSTEM (LATER MODELS)....2244
      Radiator / Oil Cooler Removal And Installation....2244
      Hydraulic Fan Description....2247
      Fan Duct Removal And Installation....2247
      Hydraulic Fan Motor Assembly Removal And Installation....2248
      Hydraulic Fan Motor Removal And Installation....2249
      Hydraulic Fan Motor Disassembly And Assembly....2251
      Blower Housing Removal And Installation....2252
      Water Pump Removal And Installation....2253
      Water Pump Disassembly And Assembly....2253
      Thermostat Housing Removal And Installation....2254
      Thermostat - Testing....2255
    LUBRICATION SYSTEM....2256
      Oil Pan Removal And Installation....2256
      Oil Pump Removal And Installation....2256
      Relief Valve - Testing....2257
      Oil Pump Inspection....2257
      Oil Filter Cooler Removal And Installation....2258
      Engine Oil Pressure - Testing....2259
    FUEL SYSTEM....2260
      Fuel Shutoff Solenoid - Testing....2260
      Fuel Shutoff Solenoid Removal And Installation....2260
      Fuel Injection Pump - Testing....2261
      Fuel Injection Pump Assembly Removal And Installation....2262
      Governor Housing Disassembly And Assembly....2265
      Governor Disassembly And Assembly....2267
      Fuel Camshaft Removal And Installation....2269
      Fuel Injection Pump Removal And Installation....2271
      Fuel Injection Pump - Timing....2273
      Fuel Injector Removal And Installation....2275
      Fuel Injector Nozzle Pressure - Testing....2276
      Nozzle Spray Condition....2277
      Valve Seat Tightness....2277
    CYLINDER HEAD....2278
      Glow Plugs - Testing....2278
      Glow Plugs Removal And Installation....2278
      Valve Clearance Adjustment....2279
      Valve Timing - Inspecting....2280
      Cylinder Head Removal And Installation....2281
      Cylinder Head Disassembly And Assembly....2284
      Cylinder Head - Servicing....2284
      Cylinder Head Top Clearance....2285
      Valve Guide - Inspecting....2285
      Valve Guide Removal And Installation....2286
      Reconditioning The Valve And Valve Seat....2286
      Valve Spring....2288
      Valve Tappets....2289
      Rocker Arm And Shaft - Checking....2290
      Bridge Arm And Bridge Arm Shaft - Checking....2290
      Bridge Arm Shaft - Removal And Installation....2291
      Push Rod Alignment - Inspecting....2292
    CRANKSHAFT AND PISTONS....2294
      Piston And Connecting Rod Removal And Installation....2294
      Piston And Connecting Rod - Servicing....2295
      Cylinder Bore - Checking....2298
      Connecting Rod Alignment....2299
      Crankshaft Gear Removal And Installation....2299
      Crankshaft And Bearings Removal And Installation....2300
      Crankshaft And Bearings - Servicing....2302
    CAMSHAFT AND TIMING GEARS....2306
      Timing Gearcase Cover Removal....2306
      Timing Gearcase Cover Installation....2307
      Timing Gears Backlash - Measuring....2310
      Idler Gear And Camshaft Removal And Installation....2310
      Camshaft - Servicing....2311
      Idler Gear And Shaft - Servicing....2312
    TURBOCHARGER....2314
      Description....2314
      Testing....2314
      Removal And Installation....2315
    FLYWHEEL AND HOUSING....2318
      Flywheel Removal And Installation....2318
      Ring Gear Removal And Installation....2320
      Housing Removal And Installation....2320
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM....2322
      Description....2322
      Testing....2323
      Removal And Installation....2326
      Disassembly And Assembly....2327
  HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....2328
    AIR CONDITIONING SYSTEM FLOW....2331
      Description....2331
      Chart....2332
      Components....2333
      Safety Equipment....2336
    REGULAR MAINTENANCE....2338
      Filters....2338
      Compressor Drive Belt Adjustment....2339
      Compressor Drive Belt Replacement....2339
      Condenser....2339
      Air Conditioning Lubrication....2339
      Air Conditioning Service Chart....2340
      Evaporator / Heater Coil....2341
    TROUBLESHOOTING....2342
      Blower Motor Does Not Operate....2342
      Blower Motor Operates Normally, But Air Flow Is Insufficient....2342
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....2342
      The Compressor Does Not Operate At All, Or Operates Improperly....2342
      Gauge Pressure Related Troubleshooting....2343
      Troubleshooting Tree....2345
      Temperature / Pressure Chart....2349
      Poor A/C Performance....2351
      HVAC Repair And Leaks....2352
      Electrical System....2353
      Engine Coolant Bypassing The Heater Valve....2359
      Heater Valve Not Opening Or Closing....2361
    SYSTEM CHARGING AND RECLAMATION....2362
      Refrigerant Identification....2362
      Reclamation And Charging With Recovery / Charging Unit....2363
    COMPRESSOR....2366
      Removal And Installation....2366
      Oil....2368
      Oil Check....2369
    CONDENSER (EARLY MODELS)....2370
      Removal And Installation....2370
    CONDENSER (LATER MODELS)....2372
      Removal And Installation....2372
    RECEIVER / DRIER (early models)....2374
      Receiver / Drier Removal And Installation....2374
      Pressure Relief Valve Removal And Installation....2375
      Pressure Switch Removal And Installation....2376
      Schraeder Valve Removal And Installation....2377
    RECEIVER / DRIER (LATER MODELS)....2378
      Receiver / Drier Removal And Installation....2378
      Pressure Switch Removal And Installation....2380
      Schraeder Valve Removal And Installation....2381
    EVAPORATOR / HEATER UNIT....2382
      Removal And Installation (Early Models)....2382
      Removal And Installation (Later Models)....2383
    THERMOSTAT....2384
      Description....2384
      Removal And Installation (Early Models)....2385
      Removal And Installation (Later Models)....2386
    EXPANSION VALVE....2388
      Removal And Installation (Early Models)....2388
      Removal And Installation (Later Models)....2390
    EVAPORATOR COIL....2392
      Removal And Installation (Early Models)....2392
      Removal And Installation (Later Models)....2394
    HEATER COIL....2396
      Removal And Installation (Early Models)....2396
      Removal And Installation (Later Models)....2398
    BLOWER FAN....2400
      Removal And Installation....2400
      Disassembly And Assembly....2400
    HEATER VALVE....2404
      Removal And Installation (Early Models)....2404
      Removal And Installation (Later Models)....2405
    EVAPORATOR / HEATER COVER....2408
      Removing....2408
      Installing....2408
  SPECIFICATIONS....2410
    (T630) LOADER SPECIFICATIONS....2412
      Machine Dimensions....2412
      Performance....2413
      Engine....2413
      Drive System....2413
      Controls....2414
      Hydraulic System....2414
      Electrical System....2415
      Capacities....2415
      Tracks....2415
      Ground Pressure....2415
    TORQUE SPECIFICATIONS FOR BOLTS....2416
      Torque For General SAE Bolts....2416
      Torque For General Metric Bolts....2417
    HYDRAULIC CONNECTION SPECIFICATIONS....2418
      Straight Thread O-ring Fitting....2418
      Flare Fitting....2419
      Tubelines And Hoses....2419
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....2420
      Specifications....2420
    CONVERSIONS....2422
      Decimal And Millimeter Equivalent Chart....2422
      U.S. To Metric Conversion Chart....2422
    SERVICE TOOLS REQUIRED....2424
      Remote Start Tools....2424
      Hydraulic Tools....2425
      Mainframe And Drive Tools....2427
      Electrical Tools....2428
      Engine Tools....2428
      HVAC Tools....2432
  ALPHABETICAL INDEX....2434
6987171 (11-10) - T650 Compact Track Loader Operation & Maintenance Manual....2438
  OPERATOR SAFETY WARNINGS....2440
  CONTENTS....2442
  FOREWORD....2444
    BOBCAT COMPANY IS IS0 9001 CERTIFIED....2446
    REGULAR MAINTENANCE ITEMS....2446
    SERIAL NUMBER LOCATIONS....2447
      Loader Serial Number....2447
      Engine Serial Number....2447
    DELIVERY REPORT....2447
    LOADER IDENTIFICATION....2448
    FEATURES, ACCESSORIES AND ATTACHMENTS....2449
      Standard Items....2449
      Options And Accessories....2449
      Buckets Available....2450
      Attachments....2450
      High-Flow Attachments....2450
      Special Applications Kit....2451
      Special Applications Kit Inspection And Maintenance....2451
  SAFETY & TRAINING RESOURCES....2452
    SAFETY INSTRUCTIONS....2454
      Before Operation....2454
      Safe Operation Is The Operators Responsibility....2455
      Safe Operation Needs A Qualified Operator....2455
      Avoid Silica Dust....2456
    FIRE PREVENTION....2456
      Maintenance....2456
      Operation....2456
      Electrical....2456
      Hydraulic System....2457
      Fueling....2457
      Starting....2457
      Spark Arrestor Exhaust System....2457
      Welding And Grinding....2457
      Fire Extinguishers....2457
    PUBLICATIONS AND TRAINING RESOURCES....2458
    MACHINE SIGNS (DECALS)....2459
      No-Text Safety Signs....2462
  OPERATING INSTRUCTIONS....2464
    INSTRUMENT PANEL IDENTIFICATION....2468
      Overview....2468
      Left Panel....2469
      Display Screen....2471
      Right Panel (Standard Key Panel)....2472
      Right Panel (Keyless Start Panel)....2473
      Right Panel (Deluxe Instrumentation Panel)....2474
      Left Switch Panel....2476
      Right Switch Panel....2476
      Left Side Lower Panel....2477
      Right Side Lower Panel....2477
      Radio....2478
    CONTROL IDENTIFICATION....2480
      Standard Controls....2480
      Advanced Control System (ACS)....2481
      Selectable Joystick Controls (SJC)....2482
    OPERATOR CAB....2483
      Description....2483
      Cab Light....2483
      Door Operation....2483
      Front Wiper....2484
      Side Windows....2484
    SEAT BAR RESTRAINT SYSTEM....2485
      Operation....2485
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....2486
      Operation....2486
    LIFT ARM BYPASS CONTROL....2487
      Operation....2487
    PARKING BRAKE....2487
      Operation....2487
    TRACTION LOCK OVERRIDE....2488
      Operation....2488
    ENGINE SPEED CONTROL....2488
      Operation....2488
    EMERGENCY EXIT....2489
      External Access....2489
      Rear Window....2489
      Front Door....2489
    BACK-UP ALARM SYSTEM....2491
      Description....2491
      Operation....2491
    DRIVING AND STEERING THE LOADER....2492
      Available Control Configurations....2492
      Operation (Standard And ACS)....2492
      Operation (SJC) In ISO Control Pattern....2493
      Operation (SJC) In H Control Pattern....2494
    STOPPING THE LOADER....2494
      Using The Control Levers Or Joysticks....2494
    TWO-SPEED CONTROL....2495
      Description....2495
      Operation (Standard And ACS) (If Equipped)....2495
      Operation (SJC) (If Equipped)....2495
    SPEED MANAGEMENT....2496
      Operation....2496
      Changing The Factory Default Setting....2497
    DRIVE RESPONSE....2498
      Description....2498
      Operation....2498
    STEERING DRIFT COMPENSATION....2500
      Description....2500
      Operation....2500
    HYDRAULIC CONTROLS....2502
      Description....2502
      Standard Controls (Also ACS In FOOT Pedal Mode)....2502
      Advanced Control System (ACS) In HAND Control Mode....2503
      Selectable Joystick Controls (SJC) In ISO Control Pattern....2503
      Selectable Joystick Controls (SJC) In H Control Pattern....2504
      Hydraulic Bucket Positioning....2504
      FRONT Auxiliary Hydraulics Operation....2505
      FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....2506
      FRONT Auxiliary Hydraulics Operation (REVERSE CONTINUOUS FLOW)....2506
      REAR Auxiliary Hydraulics Operation....2507
      High-Flow Hydraulics Operation....2508
      Quick Couplers....2508
      Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....2509
    ATTACHMENT CONTROL DEVICE (ACD)....2510
      Description....2510
    DAILY INSPECTION....2511
      Daily Inspection And Maintenance....2511
    PRE-STARTING PROCEDURE....2513
      Entering The Loader....2513
      Operation & Maintenance Manual And Operators Handbook Locations....2513
      Seat Adjustment....2514
      Joystick Position Adjustment....2515
      Seat Belt Adjustment....2516
      Seat Bar....2516
    STARTING THE ENGINE....2517
      Standard Key Panel....2517
      Keyless Start Panel....2519
      Deluxe Instrumentation Panel....2521
      Cold Temperature Starting....2523
      Warming The Hydraulic / Hydrostatic System....2523
    MONITORING THE DISPLAY PANELS....2524
      Left Panel....2524
      Warning And Shutdown....2524
    STOPPING THE ENGINE AND LEAVING THE LOADER....2525
      Procedure....2525
    COUNTERWEIGHTS....2526
      Description....2526
      Effect On The Loader And Loader Operation....2526
      When To Consider Using Counterweights....2526
      When To Consider Removing Counterweights....2526
      Accessories That Affect Machine Weight....2526
    ATTACHMENTS....2527
      Choosing The Correct Bucket....2527
      Pallet Fork....2527
      Installing And Removing The Attachment (Hand Lever Bob-Tach)....2528
      Installing And Removing The Attachment (Power Bob-Tach)....2530
    TRACK UNDERCARRIAGE SYSTEM....2535
      Introduction....2535
      Compact Track Loader Operating And Maintenance Tips....2535
    OPERATING PROCEDURE....2537
      Inspect The Work Area....2537
      Basic Operating Instructions....2537
      Driving On Public Roads....2537
      Operating With A Full Bucket....2538
      Operating With An Empty Bucket....2538
      Filling And Emptying The Bucket (Foot Pedals)....2539
      Leveling The Ground Using Float (Foot Pedals)....2540
      Digging And Filling A Hole (Foot Pedals)....2540
      Filling And Emptying The Bucket (ACS - Handles, SJC - H Pattern)....2541
      Leveling The Ground Using Float (ACS - Handles, SJC - H Pattern)....2542
      Digging And Filling A Hole (ACS - Handles, SJC - H Pattern)....2543
      Filling And Emptying The Bucket (SJC - ISO Pattern)....2544
      Leveling The Ground Using Float (SJC - ISO Pattern)....2545
      Digging And Filling A Hole (SJC - ISO Pattern)....2546
    TOWING THE LOADER....2547
      Procedure....2547
    LIFTING THE LOADER....2547
      Single-Point Lift....2547
      Four-Point Lift....2548
    TRANSPORTING THE LOADER ON A TRAILER....2549
      Loading And Unloading....2549
      Fastening....2549
  PREVENTIVE MAINTENANCE....2550
    MAINTENANCE SAFETY....2554
    SERVICE SCHEDULE....2556
      Chart....2556
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....2557
      Inspecting The BICS (Engine STOPPED - Key ON)....2557
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....2557
      Inspecting The Seat Bar Sensor (Engine RUNNING)....2557
      Inspecting The Traction Lock (Engine RUNNING)....2557
      Inspecting The Lift Arm Bypass Control....2557
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....2557
    SEAT BAR RESTRAINT SYSTEM....2558
      Description....2558
      Inspecting....2558
      Maintaining....2558
    SEAT BELT....2559
      Inspection And Maintenance....2559
    LIFT ARM SUPPORT DEVICE....2560
      Installing....2560
      Removing....2561
    BACK-UP ALARM SYSTEM....2562
      Description....2562
      Inspecting....2562
      Adjusting Switch Position....2563
    OPERATOR CAB....2564
      Description....2564
      Raising....2564
      Lowering....2565
      Cab Door Sensor....2566
    REAR DOOR (TAILGATE)....2567
      Opening And Closing....2567
      Adjusting....2567
    REAR GRILLE....2568
      Removing....2568
      Installing....2568
    HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....2569
      Cleaning And Maintenance....2569
      Filters....2569
      Evaporator / Heater Coil....2570
      Condenser....2571
      Air Conditioning Lubrication....2571
      Troubleshooting....2571
    AIR CLEANER SERVICE....2571
      Replacing Filter Elements....2571
    FUEL SYSTEM....2573
      Fuel Specifications....2573
      Biodiesel Blend Fuel....2573
      Filling The Fuel Tank....2574
      Fuel Filter....2575
      Removing Air From The Fuel System....2575
    ENGINE LUBRICATION SYSTEM....2576
      Checking And Adding Engine Oil....2576
      Engine Oil Chart....2576
      Removing And Replacing Oil And Filter....2577
    ENGINE COOLING SYSTEM....2578
      Maintenance Platform....2578
      Cleaning....2578
      Checking Level....2580
      Removing And Replacing Coolant....2580
    ELECTRICAL SYSTEM....2581
      Description....2581
      Fuse And Relay Location / Identification....2581
      Battery Maintenance....2584
      Using A Booster Battery (Jump Starting)....2585
      Removing And Installing Battery....2586
    HYDRAULIC / HYDROSTATIC SYSTEM....2587
      Checking And Adding Fluid....2587
      Hydraulic / Hydrostatic Fluid Chart....2587
      Removing And Replacing Hydraulic Fluid....2588
      Removing And Replacing Hydraulic / Hydrostatic Filter....2590
      Removing And Replacing Hydraulic Charge Filter....2592
      Breather Cap....2593
    SPARK ARRESTER MUFFLER....2594
      Cleaning Procedure....2594
    TRACK TENSION....2595
      Description....2595
      Checking (Solid-Mounted Undercarriage)....2596
      Adjusting (Solid-Mounted Undercarriage)....2597
      Checking (Roller Suspension Undercarriage)....2598
      Adjusting (Roller Suspension Undercarriage)....2599
    HYDROSTATIC DRIVE MOTOR....2600
      Removing And Replacing Oil....2600
    TRACK SPROCKET MAINTENANCE....2600
      Tightening Procedure....2600
    ALTERNATOR BELT....2601
      Belt Adjustment....2601
      Belt Replacement....2601
    AIR CONDITIONING BELT....2602
      Belt Adjustment....2602
      Belt Replacement....2602
    DRIVE BELT....2603
      Belt Adjustment....2603
      Stop Adjustment....2603
      Belt Replacement....2603
    LUBRICATING THE LOADER....2605
      Lubrication Locations....2605
    TRACK ROLLER AND IDLER LUBRICATION....2607
      Procedure....2607
    PIVOT PINS....2607
      Inspection And Maintenance....2607
    BOB-TACH (HAND LEVER)....2608
      Inspection And Maintenance....2608
    BOB-TACH (POWER)....2609
      Inspection And Maintenance....2609
    LOADER STORAGE AND RETURN TO SERVICE....2610
      Storage....2610
      Return To Service....2610
  SYSTEM SETUP & ANALYSIS....2612
    DIAGNOSTIC SERVICE CODES....2614
      Viewing Service Codes....2614
      Service Codes List....2615
    CONTROL PANEL SETUP....2620
      Right Panel Setup (Deluxe Instrumentation Panel)....2620
    PASSWORD SETUP (KEYLESS START PANEL)....2622
      Password Description....2622
      Changing The Owner Password....2622
      Password Lockout Feature....2622
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....2623
      Password Description....2623
      Changing The Owner Password....2623
      Changing The User Passwords....2624
      Password Lockout Feature....2624
    MAINTENANCE CLOCK....2625
      Description....2625
      Setup....2625
      Reset....2625
  MACHINE SIGN TRANSLATIONS....2626
    MACHINE SIGN TRANSLATIONS....2628
      Service Schedule (7167998)....2628
      Warning (7167993)....2631
      Warning (7169291)....2631
      Danger (7167989)....2631
      Danger (7167990)....2631
      Danger (7167988)....2632
      Warning (7168114)....2632
      Warning (7167994)....2633
      Warning (7168140)....2634
      Warning (7168142)....2634
      Warning (7168138)....2635
      Warning (7167996)....2636
      Warning (7167995)....2636
      Warning (7184346)....2637
      Danger (7170355)....2637
      Warning (6737189)....2638
      Lift Arm Support Device (7169340)....2639
      Warning (7168024)....2640
      Warning (7142141)....2641
      Warning (7168019)....2642
  SPECIFICATIONS....2644
    (T650) LOADER SPECIFICATIONS....2646
      Machine Dimensions....2646
      Performance....2647
      Engine....2647
      Drive System....2647
      Controls....2648
      Hydraulic System....2648
      Electrical System....2649
      Capacities....2649
      Tracks....2649
      Ground Pressure....2649
  WARRANTY....2650
    WARRANTY....2652
  ALPHABETICAL INDEX....2654
6987171 (3-11) - T650 Compact Track Loader Operation & Maintenance Manual....2656
  OPERATOR SAFETY WARNINGS....2658
  CONTENTS....2660
  FOREWORD....2662
    BOBCAT COMPANY IS IS0 9001 CERTIFIED....2664
    REGULAR MAINTENANCE ITEMS....2664
    SERIAL NUMBER LOCATIONS....2665
      Loader Serial Number....2665
      Engine Serial Number....2665
    DELIVERY REPORT....2665
    LOADER IDENTIFICATION....2666
    FEATURES, ACCESSORIES AND ATTACHMENTS....2667
      Standard Items....2667
      Options And Accessories....2667
      Buckets Available....2668
      Attachments....2668
      High-Flow Attachments....2668
      Special Applications Kit....2669
      Special Applications Kit Inspection And Maintenance....2669
  SAFETY & TRAINING RESOURCES....2670
    SAFETY INSTRUCTIONS....2672
      Before Operation....2672
      Safe Operation Is The Operators Responsibility....2673
      Safe Operation Needs A Qualified Operator....2673
      Avoid Silica Dust....2674
    FIRE PREVENTION....2674
      Maintenance....2674
      Operation....2674
      Electrical....2674
      Hydraulic System....2675
      Fueling....2675
      Starting....2675
      Spark Arrestor Exhaust System....2675
      Welding And Grinding....2675
      Fire Extinguishers....2675
    PUBLICATIONS AND TRAINING RESOURCES....2676
    MACHINE SIGNS (DECALS)....2677
      No-Text Safety Signs....2680
  OPERATING INSTRUCTIONS....2682
    INSTRUMENT PANEL IDENTIFICATION....2686
      Overview....2686
      Left Panel....2687
      Display Screen....2689
      Right Panel (Standard Key Panel)....2690
      Right Panel (Keyless Start Panel)....2691
      Right Panel (Deluxe Instrumentation Panel)....2692
      Left Switch Panel....2694
      Right Switch Panel....2694
      Left Side Lower Panel....2695
      Right Side Lower Panel....2695
      Radio....2696
    CONTROL IDENTIFICATION....2698
      Standard Controls....2698
      Advanced Control System (ACS)....2699
      Selectable Joystick Controls (SJC)....2700
    OPERATOR CAB....2701
      Description....2701
      Cab Light....2701
      Door Operation....2701
      Front Wiper....2702
      Side Windows....2702
    SEAT BAR RESTRAINT SYSTEM....2703
      Operation....2703
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....2704
      Operation....2704
    LIFT ARM BYPASS CONTROL....2705
      Operation....2705
    PARKING BRAKE....2705
      Operation....2705
    TRACTION LOCK OVERRIDE....2706
      Operation....2706
    ENGINE SPEED CONTROL....2706
      Operation....2706
    EMERGENCY EXIT....2707
      External Access....2707
      Rear Window....2707
      Front Door....2707
    BACK-UP ALARM SYSTEM....2709
      Description....2709
      Operation....2709
    DRIVING AND STEERING THE LOADER....2710
      Available Control Configurations....2710
      Operation (Standard And ACS)....2710
      Operation (SJC) In ISO Control Pattern....2711
      Operation (SJC) In H Control Pattern....2712
    STOPPING THE LOADER....2712
      Using The Control Levers Or Joysticks....2712
    TWO-SPEED CONTROL....2713
      Description....2713
      Operation (Standard And ACS) (If Equipped)....2713
      Operation (SJC) (If Equipped)....2713
    SPEED MANAGEMENT....2714
      Operation....2714
      Changing The Factory Default Setting....2715
    DRIVE RESPONSE....2716
      Description....2716
      Operation....2716
    STEERING DRIFT COMPENSATION....2718
      Description....2718
      Operation....2718
    HYDRAULIC CONTROLS....2720
      Description....2720
      Standard Controls (Also ACS In FOOT Pedal Mode)....2720
      Advanced Control System (ACS) In HAND Control Mode....2721
      Selectable Joystick Controls (SJC) In ISO Control Pattern....2721
      Selectable Joystick Controls (SJC) In H Control Pattern....2722
      Hydraulic Bucket Positioning....2722
      FRONT Auxiliary Hydraulics Operation....2723
      FRONT Auxiliary Hydraulics Operation (CONTINUOUS FLOW)....2724
      FRONT Auxiliary Hydraulics Operation (REVERSE CONTINUOUS FLOW)....2724
      REAR Auxiliary Hydraulics Operation....2725
      High-Flow Hydraulics Operation....2726
      Quick Couplers....2726
      Relieve Auxiliary Hydraulic Pressure (Loader And Attachment)....2727
    ATTACHMENT CONTROL DEVICE (ACD)....2728
      Description....2728
    DAILY INSPECTION....2729
      Daily Inspection And Maintenance....2729
    PRE-STARTING PROCEDURE....2731
      Entering The Loader....2731
      Operation & Maintenance Manual And Operators Handbook Locations....2731
      Seat Adjustment....2732
      Joystick Position Adjustment....2733
      Seat Belt Adjustment....2734
      Seat Bar....2734
    STARTING THE ENGINE....2735
      Standard Key Panel....2735
      Keyless Start Panel....2737
      Deluxe Instrumentation Panel....2739
      Cold Temperature Starting....2741
      Warming The Hydraulic / Hydrostatic System....2741
    MONITORING THE DISPLAY PANELS....2742
      Left Panel....2742
      Warning And Shutdown....2742
    STOPPING THE ENGINE AND LEAVING THE LOADER....2743
      Procedure....2743
    COUNTERWEIGHTS....2744
      Description....2744
      Effect On The Loader And Loader Operation....2744
      When To Consider Using Counterweights....2744
      When To Consider Removing Counterweights....2744
      Accessories That Affect Machine Weight....2744
    ATTACHMENTS....2745
      Choosing The Correct Bucket....2745
      Pallet Fork....2745
      Installing And Removing The Attachment (Hand Lever Bob-Tach)....2746
      Installing And Removing The Attachment (Power Bob-Tach)....2748
    TRACK UNDERCARRIAGE SYSTEM....2753
      Introduction....2753
      Compact Track Loader Operating And Maintenance Tips....2753
    OPERATING PROCEDURE....2755
      Inspect The Work Area....2755
      Basic Operating Instructions....2755
      Driving On Public Roads....2755
      Operating With A Full Bucket....2756
      Operating With An Empty Bucket....2756
      Filling And Emptying The Bucket (Foot Pedals)....2757
      Leveling The Ground Using Float (Foot Pedals)....2758
      Digging And Filling A Hole (Foot Pedals)....2759
      Filling And Emptying The Bucket (ACS - Handles, SJC - H Pattern)....2760
      Leveling The Ground Using Float (ACS - Handles, SJC - H Pattern)....2761
      Digging And Filling A Hole (ACS - Handles, SJC - H Pattern)....2762
      Filling And Emptying The Bucket (SJC - ISO Pattern)....2763
      Leveling The Ground Using Float (SJC - ISO Pattern)....2764
      Digging And Filling A Hole (SJC - ISO Pattern)....2765
    TOWING THE LOADER....2766
      Procedure....2766
    LIFTING THE LOADER....2766
      Single-Point Lift....2766
      Four-Point Lift....2767
    TRANSPORTING THE LOADER ON A TRAILER....2768
      Loading And Unloading....2768
      Fastening....2768
  PREVENTIVE MAINTENANCE....2770
    MAINTENANCE SAFETY....2774
    SERVICE SCHEDULE....2776
      Chart....2776
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....2777
      Inspecting The BICS (Engine STOPPED - Key ON)....2777
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....2777
      Inspecting The Seat Bar Sensor (Engine RUNNING)....2777
      Inspecting The Traction Lock (Engine RUNNING)....2777
      Inspecting The Lift Arm Bypass Control....2777
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....2777
    SEAT BAR RESTRAINT SYSTEM....2778
      Description....2778
      Inspecting....2778
      Maintaining....2778
    SEAT BELT....2779
      Inspection And Maintenance....2779
    LIFT ARM SUPPORT DEVICE....2780
      Installing....2780
      Removing....2781
    BACK-UP ALARM SYSTEM....2782
      Description....2782
      Inspecting....2782
      Adjusting Switch Position....2783
    OPERATOR CAB....2784
      Description....2784
      Raising....2784
      Lowering....2785
      Cab Door Sensor....2786
    REAR DOOR (TAILGATE)....2787
      Opening And Closing....2787
      Adjusting....2787
    REAR GRILLE....2788
      Removing....2788
      Installing....2788
    HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....2789
      Cleaning And Maintenance....2789
      Filters....2789
      Evaporator / Heater Coil....2790
      Condenser....2791
      Air Conditioning Lubrication....2791
      Troubleshooting....2791
    AIR CLEANER SERVICE....2791
      Replacing Filter Elements....2791
    FUEL SYSTEM....2793
      Fuel Specifications....2793
      Biodiesel Blend Fuel....2793
      Filling The Fuel Tank....2794
      Fuel Filter....2795
      Removing Air From The Fuel System....2795
    ENGINE LUBRICATION SYSTEM....2796
      Checking And Adding Engine Oil....2796
      Engine Oil Chart....2796
      Removing And Replacing Oil And Filter....2797
    ENGINE COOLING SYSTEM....2798
      Maintenance Platform....2798
      Cleaning....2798
      Checking Level....2800
      Removing And Replacing Coolant....2800
    ELECTRICAL SYSTEM....2801
      Description....2801
      Fuse And Relay Location / Identification....2801
      Battery Maintenance....2804
      Using A Booster Battery (Jump Starting)....2805
      Removing And Installing Battery....2806
    HYDRAULIC / HYDROSTATIC SYSTEM....2807
      Checking And Adding Fluid....2807
      Hydraulic / Hydrostatic Fluid Chart....2807
      Removing And Replacing Hydraulic Fluid....2808
      Removing And Replacing Hydraulic / Hydrostatic Filter....2810
      Removing And Replacing Hydraulic Charge Filter....2812
      Breather Cap....2813
    SPARK ARRESTER MUFFLER....2814
      Cleaning Procedure....2814
    TRACK TENSION....2815
      Description....2815
      Checking (Solid-Mounted Undercarriage)....2816
      Adjusting (Solid-Mounted Undercarriage)....2817
      Checking (Roller Suspension Undercarriage)....2818
      Adjusting (Roller Suspension Undercarriage)....2819
    HYDROSTATIC DRIVE MOTOR....2820
      Removing And Replacing Oil....2820
    TRACK SPROCKET MAINTENANCE....2820
      Tightening Procedure....2820
    ALTERNATOR BELT....2821
      Belt Adjustment....2821
      Belt Replacement....2821
    AIR CONDITIONING BELT....2822
      Belt Adjustment....2822
      Belt Replacement....2822
    DRIVE BELT....2823
      Belt Adjustment....2823
      Stop Adjustment....2823
      Belt Replacement....2823
    LUBRICATING THE LOADER....2825
      Lubrication Locations....2825
    TRACK ROLLER AND IDLER LUBRICATION....2827
      Procedure....2827
    PIVOT PINS....2827
      Inspection And Maintenance....2827
    BOB-TACH (HAND LEVER)....2828
      Inspection And Maintenance....2828
    BOB-TACH (POWER)....2829
      Inspection And Maintenance....2829
    LOADER STORAGE AND RETURN TO SERVICE....2830
      Storage....2830
      Return To Service....2830
  SYSTEM SETUP & ANALYSIS....2832
    DIAGNOSTIC SERVICE CODES....2834
      Viewing Service Codes....2834
      Service Codes List....2835
    CONTROL PANEL SETUP....2840
      Right Panel Setup (Deluxe Instrumentation Panel)....2840
    PASSWORD SETUP (KEYLESS START PANEL)....2842
      Password Description....2842
      Changing The Owner Password....2842
      Password Lockout Feature....2842
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....2843
      Password Description....2843
      Changing The Owner Password....2843
      Changing The User Passwords....2844
      Password Lockout Feature....2844
    MAINTENANCE CLOCK....2845
      Description....2845
      Setup....2845
      Reset....2845
  MACHINE SIGN TRANSLATIONS....2846
    MACHINE SIGN TRANSLATIONS....2848
      Service Schedule (7167998)....2848
      Warning (7167993)....2851
      Warning (7169291)....2851
      Danger (7167989)....2851
      Danger (7167990)....2851
      Danger (7167988)....2852
      Warning (7168114)....2852
      Warning (7167994)....2853
      Warning (7168140)....2854
      Warning (7168142)....2854
      Warning (7168138)....2855
      Warning (7167996)....2856
      Warning (6737189)....2856
      Warning (7184346)....2857
      Danger (7170355)....2857
      Lift Arm Support Device (7169340)....2858
      Warning (7168024)....2859
      Warning (7142141)....2860
      Warning (7168019)....2861
  SPECIFICATIONS....2862
    (T650) LOADER SPECIFICATIONS....2864
      Machine Dimensions....2864
      Performance....2865
      Engine....2865
      Drive System....2865
      Controls....2866
      Hydraulic System....2866
      Electrical System....2867
      Capacities....2867
      Tracks....2867
      Ground Pressure....2867
  WARRANTY....2868
    WARRANTY....2870
  ALPHABETICAL INDEX....2872
6987172 (05-14) - T650 Compact Track Loader Service Manual....2874
  MAINTENANCE SAFETY....2876
  CONTENTS....2878
  FOREWORD....2880
    FOREWORD....2882
    SAFETY INSTRUCTIONS....2884
    FIRE PREVENTION....2886
      Maintenance....2886
      Operation....2886
      Electrical....2886
      Hydraulic System....2886
      Fueling....2886
      Starting....2886
      Spark Arrester Exhaust System....2886
      Welding And Grinding....2887
      Fire Extinguishers....2887
    SERIAL NUMBER LOCATIONS....2888
      Loader Serial Number....2888
      Engine Serial Number....2888
    DELIVERY REPORT....2889
    LOADER IDENTIFICATION....2890
  SAFETY & MAINTENANCE....2892
    LIFTING AND BLOCKING THE LOADER....2896
      Procedure....2896
    LIFT ARM SUPPORT DEVICE....2898
      Installing....2898
      Removing....2899
    OPERATOR CAB....2900
      Description....2900
      Raising....2901
      Lowering....2902
      Cab Door Sensor....2903
      Special Application Kit....2904
      Special Applications Kit Inspection And Maintenance....2904
      Forestry Door And Window Kit....2905
      Forestry Door And Window Kit Inspection And Maintenance....2905
    TRANSPORTING THE LOADER ON A TRAILER....2906
      Loading And Unloading....2906
      Fastening....2906
    TOWING THE LOADER....2908
      Procedure....2908
    REMOTE START TOOL KIT- MEL1563....2910
      Remote Start Tool - MEL1563....2910
      Service Tool Harness Communicator - MEL1566....2911
      Remote Start Procedure....2912
    REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....2916
      Description....2916
      Remote Start Tool (Service Tool) - 7022042....2917
      Loader Service Tool Harness - 6689747....2918
      Computer Service Tool Harness - 6689746....2919
      Remote Start Procedure....2920
    SERVICE SCHEDULE....2924
      Chart....2924
    AIR CLEANER SERVICE....2926
      Replacing Filter Elements....2926
    ENGINE COOLING SYSTEM....2928
      Maintenance Platform....2928
      Cooling System Identification....2928
      Cleaning (Earlier Models)....2929
      Cleaning (Later Models)....2931
      Checking Level....2933
      Removing And Replacing Coolant....2933
    FUEL SYSTEM....2934
      Fuel Specifications....2934
      Biodiesel Blend Fuel....2934
      Filling The Fuel Tank....2935
      Fuel Filter....2936
      Removing Air From The Fuel System....2936
    ENGINE LUBRICATION SYSTEM....2938
      Checking And Adding Engine Oil....2938
      Engine Oil Chart....2938
      Removing And Replacing Oil And Filter....2939
    HYDRAULIC / HYDROSTATIC SYSTEM....2942
      Checking And Adding Fluid....2942
      Hydraulic / Hydrostatic Fluid Chart....2942
      Removing And Replacing Hydraulic Fluid....2943
      Removing And Replacing Hydraulic / Hydrostatic Filter....2945
      Removing And Replacing Hydraulic Charge Filter....2947
      Breather Cap....2948
    BOB-TACH (HAND LEVER)....2950
      Inspection And Maintenance....2950
    BOB-TACH (POWER)....2952
      Inspection And Maintenance....2952
    LUBRICATING THE LOADER....2954
      Lubrication Locations....2954
    SPARK ARRESTER MUFFLER....2958
      Cleaning Procedure....2958
    PIVOT PINS....2960
      Inspection And Maintenance....2960
    LOADER STORAGE AND RETURN TO SERVICE....2962
      Storage....2962
      Return To Service....2962
    STOPPING THE ENGINE AND LEAVING THE LOADER....2964
      Procedure....2964
    EMERGENCY EXIT....2966
      Rear Window Identification....2966
      Rear Window Removal (Latches)....2966
      Rear Window Removal (Rubber Cord)....2966
      External Access (Rear Window With Latches)....2967
      External Access (Rear Window With Rubber Cord)....2967
      Front Door....2967
    SEAT BELT....2970
      Inspection And Maintenance....2970
  HYDRAULIC SYSTEM....2972
    HYDRAULIC/HYDROSTATIC SCHEMATICS....2978
    HYDRAULIC SYSTEM INFORMATION....2994
      Glossary Of Hydraulic / Hydrostatic Symbols....2994
      Troubleshooting....2998
    CYLINDER (LIFT)....3000
      Testing....3000
      Removal And Installation....3001
      Parts Identification....3005
      Disassembly....3006
      Assembly....3008
    CYLINDER (TILT)....3012
      Testing....3012
      Removal And Installation....3013
      Base End Pivot Pin Removal And Installation....3015
      Parts Identification (Early Models)....3016
      Parts Identification (Later Models)....3017
      Disassembly....3018
      Assembly....3020
    CYLINDER (BOB-TACH)....3024
      Testing....3024
      Removal And Installation....3025
      Parts Identification....3026
      Disassembly....3027
      Assembly....3028
    MAIN RELIEF VALVE (early models)....3032
      Description....3032
      Testing....3033
      Adjusting....3035
      Removal And Installation....3036
    MAIN RELIEF VALVE (LATER MODELS)....3038
      Description....3038
      Testing....3039
      Main Relief Valve Adjustment....3041
      Main Relief Valve Removal And Installation....3041
      Auxiliary Relief Valve Adjustment....3042
      Auxiliary Relief Valve Removal And Installation....3043
    HYDRAULIC CONTROL VALVE (STANDARD) (early models)....3044
      Description....3044
      Removal And Installation....3045
      Mount Bracket Removal And Installation....3048
      Identification Chart....3049
      Lift Load Check Valve Removal And Installation....3050
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....3051
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....3052
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....3052
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....3053
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....3053
      Port Relief Valve Removal And Installation....3054
      Plug Removal And Installation....3055
      Rubber Boot Removal And Installation....3056
      End Cap Block Removal And Installation....3057
      Lift Spool And Detent Removal And Installation....3058
      Tilt Spool Removal And Installation....3068
      Auxiliary Spool Removal And Installation....3070
      Auxiliary Solenoid Removal And Installation....3071
      Solenoid Removal And Installation....3072
      Lock Valve Removal And Installation....3073
      Lift Arm Bypass Orifice Removal And Installation....3075
      Main Relief Valve Removal And Installation....3075
      Check Valve Removal And Installation....3076
    HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS)....3078
      Description....3078
      Removal And Installation....3079
      Mount Bracket Removal And Installation....3082
      Identification Chart....3083
      Lift Load Check Valve Removal And Installation....3084
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....3085
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....3086
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....3086
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....3087
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....3087
      Port Relief Valve Removal And Installation....3088
      Plug Removal And Installation....3090
      Rubber Boot Removal And Installation....3091
      End Cap Block Removal And Installation....3091
      Lift Spool And Detent Removal And Installation....3092
      Tilt Spool Removal And Installation....3100
      Auxiliary Spool Removal And Installation....3102
      Auxiliary Solenoid Removal And Installation....3103
      Solenoid Removal And Installation....3104
      Lock Valve Removal And Installation....3105
      Lift Arm Bypass Orifice Removal And Installation....3107
      Main Relief Valve Removal And Installation....3107
      Auxiliary Relief Valve Removal And Installation....3108
      Check Valve Removal And Installation....3108
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLY MODELS)....3110
      Description....3110
      Removal And Installation....3111
      Actuator Removal And Installation (In Loader)....3115
      Actuator Removal And Installation (Out Of Loader)....3117
      Identification Chart....3120
      Mount Bracket Removal And Installation....3121
      Lift Load Check Valve Removal And Installation....3121
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....3122
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....3123
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....3123
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....3124
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....3124
      Port Relief Valve Removal And Installation....3125
      Plug Removal And Installation....3126
      End Cap Block Removal And Installation....3127
      Lift Spool Removal And Installation....3128
      Tilt Spool Removal And Installation....3133
      Auxiliary Spool Removal And Installation....3135
      Auxiliary Solenoid Removal And Installation....3136
      Solenoid Removal And Installation....3137
      Lock Valve Removal And Installation....3138
      Lift Arm Bypass Orifice Removal And Installation....3139
      Main Relief Valve Removal And Installation....3139
      Check Valve Removal And Installation....3140
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS)....3142
      Description....3142
      Removal And Installation....3142
      Actuator Removal And Installation (In Loader)....3146
      Actuator Removal And Installation (Out Of Loader)....3147
      Identification Chart....3150
      Mount Bracket Removal And Installation....3151
      Lift Load Check Valve Removal And Installation....3151
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....3152
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....3153
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....3153
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....3154
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....3154
      Port Relief Valve Removal And Installation....3155
      Plug Removal And Installation....3157
      End Cap Block Removal And Installation....3158
      Lift Spool Removal And Installation....3158
      Lift Spool Disassembly And Assembly....3160
      Tilt Spool Removal And Installation....3161
      Auxiliary Spool Removal And Installation....3163
      Auxiliary Solenoid Removal And Installation....3164
      Solenoid Removal And Installation....3165
      Lock Valve Removal And Installation....3166
      Lift Arm Bypass Orifice Removal And Installation....3168
      Main Relief Valve Removal And Installation....3168
      Auxiliary Relief Valve Removal And Installation....3169
      Check Valve Removal And Installation....3169
    LIFT ARM BYPASS CONTROL VALVE....3172
      Description....3172
      Testing....3172
      Removal And Installation....3173
      Bracket Removal And Installation....3174
      Disassembly And Assembly....3174
    HYDRAULIC PUMP....3176
      Description....3176
      Pump Test At Quick Couplers....3177
      Direct Pump Test (Standard Section)....3178
      Direct Pump Test (Charge Section)....3180
      Removal And Installation....3182
      Hydraulic Pump Startup....3184
      Parts Identification....3185
      Disassembly And Assembly....3186
    HYDRAULIC PUMP (HIGH FLOW)....3188
      Description....3188
      Pump Test At Quick Couplers....3189
      Direct Pump Test (Standard Section)....3190
      Direct Pump Test (Charge Section)....3192
      Direct Pump Test (High Flow Section)....3194
      High Flow Relief Valve Adjustment....3196
      High Flow Relief Valve Removal And Installation....3197
      Solenoid Removal And Installation....3198
      Removal And Installation....3199
      Removal And Installation (Contd)....3201
      Hydraulic Pump Startup....3201
      Parts Identification....3202
      Disassembly And Assembly....3203
    HYDRAULIC / HYDROSTATIC FILTERS....3204
      Description....3204
      Housing Removal And Installation....3205
    HYDRAULIC FLUID RESERVOIR....3206
      Description....3206
      Removal And Installation....3206
      Hydraulic Fluid Screen....3207
    OIL COOLER....3208
      Description....3208
      Removal And Installation....3209
    BUCKET POSITION VALVE....3212
      Description....3212
      Solenoid Removal And Installation....3212
      Solenoid Testing....3213
      Removal And Installation....3213
      Disassembly And Assembly....3215
    REAR AUXILIARY DIVERTER VALVE....3216
      Description....3216
      Solenoid Testing....3217
      Removal And Installation....3218
      Disassembly And Assembly....3220
    BOB-TACH (POWER) BLOCK....3226
      Description....3226
      Removal And Installation....3226
      Disassembly And Assembly (Early Models)....3228
      Disassembly And Assembly (Later Models)....3232
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....3240
      Description....3240
      Removal And Installation....3240
      Disassembly And Assembly....3241
  HYDROSTATIC SYSTEM....3244
    HYDROSTATIC SYSTEM INFORMATION....3246
      Description....3246
      Troubleshooting....3247
    HYDROSTATIC DRIVE MOTOR....3248
      Description....3248
      Removing And Replacing Fluid....3248
      Removal And Installation....3249
      Parts Identification....3251
      Disassembly And Assembly....3253
    HYDROSTATIC DRIVE MOTOR (TWO SPEED) (s/n a3p011001-14874, a3p111001-12374)....3266
      Description....3266
      Removing And Replacing Fluid....3266
      Removal And Installation....3267
      Parts Identification....3269
      Disassembly And Assembly....3271
    HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N A3p014875 & ABOVE AND S/N a3p112375 & ABOVE)....3284
      Description....3284
      Removing And Replacing Fluid....3284
      Removal And Installation....3285
      Parts Identification....3287
      Disassembly And Assembly....3289
    CHARGE PRESSURE....3302
      Description....3302
      Testing....3302
      Sender Removal And Installation....3304
      Adjusting....3305
    HYDROSTATIC PUMP....3308
      Description....3308
      Removal And Installation....3309
      Hydrostatic Pump Startup....3310
      Replenishing / High Pressure Relief Valve Removal And Installation....3311
      Parts Identification (Left Half)....3312
      Parts Identification (Right Half)....3313
      Disassembly....3314
      Assembly....3321
    HYDROSTATIC PUMP (SJC)....3328
      Description....3328
      Hydraulic Controller Removal And Installation....3329
      Removal And Installation....3331
      Hydrostatic Pump Startup....3333
      Parts Identification....3334
      High Pressure Relief And Bypass Valve....3335
      Charge Relief Valve....3336
      Disassembly And Assembly....3337
      Mechanical Neutral Adjustment....3350
      Hydraulic Controller Neutral Adjustment....3353
    DRIVE BELT....3356
      Belt Adjustment....3356
      Stop Adjustment....3356
      Belt Replacement....3356
      Tensioner Pulley Removal And Installation....3358
      Tensioner Pulley Disassembly And Assembly....3359
    TWO-SPEED / BRAKE VALVE (s/n a3p011001-14874, a3p111001-12374)....3360
      Description....3360
      Valve Block Removal And Installation....3361
      Valve Block Disassembly And Assembly....3363
    TWO-SPEED / BRAKE VALVE (S/N A3p014875 & ABOVE AND A3p112375 & ABOVE)....3366
      Description....3366
      Valve Block Removal And Installation....3367
      Valve Block Disassembly And Assembly....3369
    DRAIN MANIFOLD....3372
      Description....3372
      Drain Manifold Removal And Installation....3372
  DRIVE SYSTEM....3374
    BRAKE....3376
      Description....3376
      Block Removal And Installation....3376
      Block Disassembly And Assembly....3378
    BRAKE (TWO-SPEED)....3380
      Description....3380
    TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED)....3382
      Description....3382
      Checking Tension....3383
      Adjusting Tension....3384
      Track Removal And Installation....3385
      Idler (Front) Removal And Installation....3387
      Track Tensioner Disassembly And Assembly....3390
      Idler (Rear) Removal And Installation....3392
      Roller Removal And Installation....3392
      Sprocket Removal And Installation (Single Speed)....3393
      Sprocket Removal And Installation (Two Speed)....3393
      Track Housing Removal And Installation....3394
    TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION)....3396
      Description....3396
      Checking Tension....3397
      Adjusting Tension....3398
      Track Removal And Installation....3399
      Idler (Front) Removal And Installation....3401
      Track Tensioner Disassembly And Assembly....3404
      Idler (Rear) Removal And Installation....3406
      Roller Removal And Installation....3406
      Leaf Spring Removal And Installation....3407
      Sprocket Removal And Installation (Single Speed)....3408
      Sprocket Removal And Installation (Two Speed)....3408
      Track Housing Removal And Installation....3409
    TRACK MAINTENANCE....3410
      Track Damage Identification....3410
  MAINFRAME....3422
    SEAT BAR....3426
      Description....3426
      Removal And Installation....3426
      Disassembly And Assembly....3427
      Compression Spring Disassembly And Assembly....3428
    OPERATOR CAB....3430
      Gas Spring Removal And Installation....3430
      Gas Spring Bracket Disassembly And Assembly....3431
      Removal And Installation....3431
    OPERATOR SEAT (SUSPENSION)....3434
      Removal And Installation....3434
      Slide Rail Removal And Installation....3434
      Seat Belt Removal And Installation....3435
      Lower Cushion Removal....3435
      Lower Cushion Installation....3436
      Back Cushion Removal And Installation....3436
      Shock Removal And Installation....3437
      3-Point Seat Belt Removal And Installation....3437
    BOB-TACH (HAND LEVER)....3440
      Description....3440
      Removal And Installation....3441
      Lever And Wedge Disassembly And Assembly....3443
      Pivot Pin Bushing And Seal Removal And Installation....3444
    BOB-TACH (POWER)....3446
      Description....3446
      Removal And Installation....3446
      Lever And Wedge Disassembly And Assembly....3449
      Pivot Pin Bushing And Seal Removal And Installation....3450
    LIFT ARMS....3452
      Stabilizer Bar Removal And Installation....3452
      Link Removal And Installation....3453
      Removal And Installation....3455
    REAR GRILLE....3458
      Identification....3458
      Lockable Handle Rear Grille....3459
      Clamping Knob Rear Grille....3460
      Slide In Rear Grille....3461
    REAR DOOR (TAILGATE)....3464
      Removal And Installation....3464
      Striker Removal And Installation....3465
      Striker Disassembly And Assembly....3465
      Striker (Adjusting)....3465
      Latch Removal And Installation (Early Models)....3466
      Latch Removal And Installation (Later Models)....3467
    FUEL TANK....3468
      Removal And Installation....3468
      Fuel Level Sender Removal And Installation....3470
      Fuel Fill Screen Removal And Installation....3470
    CONTROL PEDALS AND LINKAGES....3472
      Description....3472
      Pedal Removal And Installation....3472
      Linkage Removal And Installation....3473
      Pedal (Adjusting)....3474
      Floor Pan Removal And Installation....3475
    CONTROL PEDALS AND LINKAGES (ACS)....3476
      Description....3476
      Pedal Removal And Installation....3476
      Linkage Removal And Installation....3477
      Pedal (Adjusting)....3477
      Floor Pan Removal And Installation....3478
    CONTROL PANEL....3480
      Description....3480
      Removal And Installation....3481
      Disassembly And Assembly....3483
      Linkage Removal And Installation....3485
      Pintle Arm Disassembly And Assembly....3488
      Linkage Neutral (Adjusting)....3489
      Linkage Travel (Adjusting)....3493
      Shock Removal And Installation....3497
    CONTROL PANEL (SJC)....3498
      Description....3498
      Removal And Installation....3498
    CONTROL HANDLE / LEVER....3500
      Description....3500
      Lever Removal And Installation....3500
      Boot Removal And Installation....3500
    CONTROL HANDLE / LEVER (ACS)....3502
      Description....3502
      Handle Sensor Removal And Installation....3502
      Handle Removal And Installation....3505
      Handle Disassembly And Assembly....3506
      Lever Removal And Installation....3506
      Boot Removal And Installation....3507
    CONTROL HANDLE / LEVER (SJC)....3508
      Description....3508
      Joystick Testing....3508
      Joystick Removal And Installation....3509
    ACCESS PANEL (INSIDE)....3510
      Removal And Installation (Left)....3510
      Removal And Installation (Right)....3510
    ACCESS PANEL (INSIDE) (SJC)....3512
      Removal And Installation (Left)....3512
      Removal And Installation (Right)....3512
    WINDOW (REAR)....3514
      Removal And Installation....3514
      Disassembly And Assembly....3514
    WINDOW (TOP)....3516
      Removal And Installation....3516
    WINDOW (SIDE)....3518
      Removal And Installation....3518
    CAB DOOR....3520
      Description....3520
      Removal And Installation....3520
      Disassembly And Assembly....3521
      Aligning....3522
      Adjusting....3523
      Checking Operation....3523
    ARMREST....3524
      Description....3524
      Removal And Installation....3525
      Disassembly And Assembly....3526
    LEFT SIDE LOWER PANEL....3530
      Removal And Installation....3530
      Disassembly And Assembly....3532
    RIGHT SIDE LOWER PANEL....3534
      Removal And Installation....3534
      Disassembly And Assembly....3536
    HEADLINER....3538
      Removal And Installation....3538
  ELECTRICAL SYSTEM & ANALYSIS....3540
    ELECTRICAL SCHEMATICS....3546
    ELECTRICAL SYSTEM INFORMATION....3662
      Glossary Of Electrical Symbols....3662
      Standard Cab Harness Connectors....3665
      Deluxe Cab Harness Connectors....3666
      Mainframe Harness Connectors....3667
      Description....3668
      Troubleshooting....3669
      Fuse And Relay Location / Identification....3670
      Solenoid Testing....3673
    BATTERY....3674
      Removal And Installation....3674
      Servicing....3675
      Using A Booster Battery (Jump Starting)....3676
    ALTERNATOR....3678
      Belt Adjustment....3678
      Belt Replacement....3678
      Charging System Inspection....3680
      Alternator Voltage Testing....3681
      Low Voltage Testing....3681
      High Voltage Testing....3682
      Removal And Installation....3683
      Parts Identification....3685
    STARTER....3686
      Testing....3686
      Removal And Installation....3686
      Parts Identification....3687
    INSTRUMENT PANELS....3688
      Left Panel (Early Models)....3688
      Left Panel (Later Models)....3690
      Display Screen....3692
      Right Panel (Standard Key Panel)....3693
      Right Panel (Keyless Start Panel)....3694
      Right Panel (Deluxe Instrumentation Panel)....3695
      Left Switch Panel....3697
      Right Switch Panel....3697
      Left Side Lower Panel....3698
      Right Side Lower Panel....3698
      Left Panel Removal And Installation....3699
      Right Panel (Standard Key Panel) Removal And Installation....3699
      Right Panel (Keyless Start Panel) Removal And Installation....3700
      Right Panel (Deluxe Instrumentation Panel) Removal And Installation....3700
      Key Switch Disassembly And Assembly....3701
      Alarm Disassembly And Assembly....3701
      Left Switch Panel Removal And Installation....3702
      Right Switch Panel Removal And Installation....3702
    LIGHTS....3704
      Front Removal And Installation....3704
      Rear Removal And Installation....3705
      Cab Light Removal And Installation....3705
    BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)....3706
      Description....3706
      Connector Identification....3707
      Removal And Installation....3713
    BOBCAT CONTROLLER (ACS)....3714
      Description....3714
      Connector And Wire Identification....3715
      Removal And Installation....3716
    BOBCAT CONTROLLER (SJC) (DRIVE)....3718
      Description....3718
      Connector Identification....3719
      Removal And Installation....3721
    SPEED SENSORS (SJC)....3722
      Description....3722
      Testing....3722
      Removal And Installation....3723
    DIAGNOSTIC SERVICE CODES....3726
      Viewing Service Codes....3726
      Service Codes List....3727
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....3732
      Description....3732
      Inspecting The BICS (Engine STOPPED - Key ON)....3733
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....3733
      Inspecting The Seat Bar Sensor (Engine RUNNING)....3733
      Inspecting The Traction Lock (Engine RUNNING)....3733
      Inspecting The Lift Arm Bypass Control....3733
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....3733
      Troubleshooting....3734
    SEAT BAR SENSOR....3736
      Description....3736
      Troubleshooting....3736
      Testing....3737
      Removal And Installation....3738
      Bobcat Interlock Control System (BICS) Circuit Test....3741
    TRACTION LOCK....3744
      Description....3744
      Troubleshooting....3745
      Inspecting....3746
    CONTROL SYSTEM (ACS)....3748
      Description....3748
      Troubleshooting....3748
      Handle Sensor Connector Disassembly And Assembly....3749
      Switch Handle Removal....3750
      Switch Handle Installation....3753
      Actuator Connector Disassembly And Assembly....3755
      Handle Lock Solenoid Removal And Installation....3756
      Handle Lock Solenoid Disassembly And Assembly....3757
      Foot Sensor Removal And Installation....3758
      Foot Sensor Disassembly And Assembly....3759
      Foot Sensor Lock Solenoid Removal And Installation....3759
    ELECTRICAL / HYDRAULIC CONTROLS....3760
      Identification Chart....3760
      Description....3761
      Identification Chart ACD Group 0....3762
      Identification Chart ACD Group 1....3763
      Identification Chart ACD Group 2....3764
      Identification Chart ACD Group 3....3765
    ELECTRICAL / HYDRAULIC CONTROLS (ACS)....3766
      Identification Chart....3766
      Description....3767
      Identification Chart ACD Group 0....3768
      Identification Chart ACD Group 1....3769
      Identification Chart ACD Group 2....3770
      Identification Chart ACD Group 3....3771
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)....3772
      Identification Chart....3772
      Description....3773
      Identification Chart ACD Group 0....3774
      Identification Chart ACD Group 1....3775
      Identification Chart ACD Group 2....3776
      Identification Chart ACD Group 3....3777
    SERVICE PC (LAPTOP COMPUTER)....3778
      Connecting Remote Start Tool....3778
      Connecting Remote Start Tool (Service Tool)....3778
    CALIBRATION....3780
      Description....3780
      Actuator Testing....3781
      Lift And Tilt Calibration (SJC)....3783
      Hydrostatic Pump Calibration (SJC)....3785
      Lift And Tilt Calibration (ACS)....3790
    STEERING DRIFT COMPENSATION....3792
      Description....3792
      Operation....3792
    FLYWHEEL RPM SENSOR....3794
      Description....3794
      Removal And Installation....3795
    CONTROL PANEL SETUP....3796
      Right Panel Setup (Deluxe Instrumentation Panel)....3796
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....3800
      Password Description....3800
      Changing The Owner Password....3800
      Changing The User Passwords....3801
      Password Lockout Feature....3801
    PASSWORD SETUP (KEYLESS START PANEL)....3802
      Password Description....3802
      Changing The Owner Password....3802
      Password Lockout Feature....3802
    MAINTENANCE CLOCK....3804
      Description....3804
      Setup....3804
      Setup....3805
      Reset....3808
    BACK-UP ALARM SYSTEM....3810
      Description....3810
      Inspecting....3810
      Adjusting Switch Position....3811
      Troubleshooting (Standard And ACS)....3812
      Troubleshooting (Joystick)....3813
      Alarm Removal And Installation....3814
      Switch Removal And Installation....3814
    FRONT HORN....3816
      Removal And Installation....3816
      Troubleshooting....3817
      Troubleshooting (Joystick)....3818
  ENGINE SERVICE....3820
    ENGINE INFORMATION....3824
      Description....3824
      Specifications....3825
      Torque Values....3828
      Troubleshooting....3828
      Engine Removal And Installation....3830
      Engine Mount Replacement....3837
      Compression - Testing....3838
    ENGINE SPEED CONTROL....3840
      Removal And Installation....3840
      Disassembly And Assembly....3840
      Cable Removal And Installation....3841
    ENGINE SPEED CONTROL (SJC) (EARLY MODELS)....3842
      Removal And Installation....3842
      Disassembly And Assembly....3843
    ENGINE SPEED CONTROL (SJC) (LATER MODELS)....3846
      Removal And Installation....3846
      Disassembly And Assembly....3847
    MUFFLER....3850
      Removal And Installation....3850
    AIR CLEANER....3852
      Housing Removal And Installation....3852
      Housing Bracket Removal And Installation....3853
    ENGINE COOLING SYSTEM (EARLY MODELS)....3854
      Radiator Removal And Installation....3854
      Hydraulic Fan Description....3856
      Fan Duct Removal And Installation....3857
      Hydraulic Fan Motor Assembly Removal And Installation....3857
      Hydraulic Fan Motor Removal And Installation....3858
      Hydraulic Fan Motor Disassembly And Assembly....3859
      Blower Housing Removal And Installation....3861
      Water Pump Removal And Installation....3861
      Water Pump Removal And Installation....3862
      Water Pump Disassembly And Assembly....3862
      Thermostat Housing Removal And Installation....3863
      Thermostat - Testing....3864
    ENGINE COOLING SYSTEM (LATER MODELS)....3866
      Radiator / Oil Cooler Removal And Installation....3866
      Hydraulic Fan Description....3869
      Fan Duct Removal And Installation....3869
      Hydraulic Fan Motor Assembly Removal And Installation....3870
      Hydraulic Fan Motor Removal And Installation....3871
      Hydraulic Fan Motor Disassembly And Assembly....3873
      Blower Housing Removal And Installation....3874
      Water Pump Removal And Installation....3875
      Water Pump Disassembly And Assembly....3875
      Thermostat Housing Removal And Installation....3876
      Thermostat - Testing....3877
    LUBRICATION SYSTEM....3878
      Oil Pan Removal And Installation....3878
      Oil Pump Removal And Installation....3878
      Relief Valve - Testing....3879
      Oil Pump Inspection....3879
      Oil Filter Cooler Removal And Installation....3880
      Engine Oil Pressure - Testing....3881
    FUEL SYSTEM....3882
      Fuel Shutoff Solenoid - Testing....3882
      Fuel Shutoff Solenoid Removal And Installation....3882
      Fuel Injection Pump - Testing....3883
      Fuel Injection Pump Assembly Removal And Installation....3884
      Governor Housing Disassembly And Assembly....3887
      Governor Disassembly And Assembly....3889
      Fuel Camshaft Removal And Installation....3891
      Fuel Injection Pump Removal And Installation....3894
      Fuel Injection Pump - Timing....3896
      Fuel Injector Removal And Installation....3898
      Fuel Injector Nozzle Pressure - Testing....3899
      Nozzle Spray Condition....3900
      Valve Seat Tightness....3900
    CYLINDER HEAD....3902
      Glow Plugs - Testing....3902
      Glow Plugs Removal And Installation....3902
      Valve Clearance Adjustment....3903
      Valve Timing - Inspecting....3904
      Cylinder Head Removal And Installation....3905
      Cylinder Head Disassembly And Assembly....3908
      Cylinder Head - Servicing....3908
      Cylinder Head Top Clearance....3909
      Valve Guide - Inspecting....3909
      Valve Guide Removal And Installation....3910
      Reconditioning The Valve And Valve Seat....3910
      Valve Spring....3912
      Valve Tappets....3913
      Rocker Arm And Shaft - Checking....3914
      Bridge Arm And Bridge Arm Shaft - Checking....3914
      Bridge Arm Shaft - Removal And Installation....3915
      Push Rod Alignment - Inspecting....3916
    CRANKSHAFT AND PISTONS....3918
      Piston And Connecting Rod Removal And Installation....3918
      Piston And Connecting Rod - Servicing....3919
      Cylinder Bore - Measuring....3922
      Connecting Rod Alignment....3923
      Crankshaft Gear Removal And Installation....3923
      Crankshaft And Bearings Removal And Installation....3924
      Crankshaft And Bearings - Servicing....3926
    CAMSHAFT AND TIMING GEARS....3930
      Timing Gearcase Cover Removal....3930
      Timing Gearcase Cover Installation....3931
      Timing Gears Backlash - Measuring....3934
      Idler Gear And Camshaft Removal And Installation....3934
      Camshaft - Servicing....3935
      Idler Gear And Shaft - Servicing....3936
    TURBOCHARGER....3938
      Description....3938
      Testing....3938
      Removal And Installation....3939
    FLYWHEEL AND HOUSING....3942
      Flywheel Removal And Installation....3942
      Ring Gear Removal And Installation....3944
      Housing Removal And Installation....3944
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM....3946
      Description....3946
      Testing....3947
      Removal And Installation....3950
      Disassembly And Assembly....3951
  HEATING, VENTILATION, AIR CONDITIONING (HVAC)....3952
    AIR CONDITIONING SYSTEM FLOW....3954
      Description....3954
      Chart....3955
      Components....3956
      Safety Equipment....3959
    REGULAR MAINTENANCE....3960
      Filters....3960
      Compressor Drive Belt Adjustment....3961
      Compressor Drive Belt Replacement....3961
      Condenser....3961
      Air Conditioning Lubrication....3961
      Air Conditioning Service Chart....3962
      Evaporator / Heater Coil....3963
    TROUBLESHOOTING....3964
      Blower Motor Does Not Operate....3964
      Blower Motor Operates Normally, But Air Flow Is Insufficient....3964
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....3964
      The Compressor Does Not Operate At All, Or Operates Improperly....3964
      Gauge Pressure Related Troubleshooting....3965
      Troubleshooting Tree....3967
      Temperature / Pressure Chart....3971
      Poor A/C Performance....3973
      HVAC Repair And Leaks....3974
      Electrical System....3975
      Engine Coolant Bypassing The Heater Valve....3982
      Heater Valve Not Opening Or Closing....3983
    SYSTEM CHARGING AND RECLAMATION....3984
      Refrigerant Identification....3984
      Reclamation And Charging With Recovery / Charging Unit....3985
    COMPRESSOR....3988
      Removal And Installation....3988
      Oil....3989
      Oil Check....3990
    CONDENSER (EARLY MODELS)....3992
      Removal And Installation....3992
    CONDENSER (LATER MODELS)....3994
      Removal And Installation....3994
    RECEIVER / DRIER (EARLY MODELS)....3996
      Receiver / Drier Removal And Installation....3996
      Pressure Relief Valve Removal And Installation....3997
      Pressure Switch Removal And Installation....3998
      Schraeder Valve Removal And Installation....3999
    RECEIVER / DRIER (LATER MODELS)....4000
      Receiver / Drier Removal And Installation....4000
      Pressure Switch Removal And Installation....4001
      Schraeder Valve Removal And Installation....4001
    EVAPORATOR / HEATER UNIT....4002
      Removal And Installation (Early Models)....4002
      Removal And Installation (Later Models)....4003
    THERMOSTAT....4004
      Description....4004
      Removal And Installation (Early Models)....4005
      Removal And Installation (Later Models)....4006
    EXPANSION VALVE....4008
      Removal And Installation (Early Models)....4008
      Removal And Installation (Later Models)....4010
    EVAPORATOR COIL....4012
      Removal And Installation (Early Models)....4012
      Removal And Installation (Later Models)....4014
    HEATER COIL (CONTD)....4016
      Removal And Installation (Early Models)....4016
      Removal And Installation (Later Models)....4018
    BLOWER FAN....4020
      Removal And Installation....4020
      Disassembly And Assembly....4021
    HEATER VALVE....4024
      Removal And Installation (Early Models)....4024
      Removal And Installation (Later Models)....4025
    EVAPORATOR / HEATER COVER....4026
      Removing....4026
      Installing....4026
  SPECIFICATIONS....4028
    (T650) LOADER SPECIFICATIONS....4030
      Machine Dimensions....4030
      Performance....4031
      Engine....4031
      Drive System....4031
      Controls....4032
      Hydraulic System....4032
      Electrical System....4033
      Capacities....4033
      Tracks....4033
      Ground Pressure....4033
    TORQUE SPECIFICATIONS FOR BOLTS....4034
      Torque For General SAE Bolts....4034
      Torque For General Metric Bolts....4035
    HYDRAULIC CONNECTION SPECIFICATIONS....4036
      Straight Thread O-ring Fitting....4036
      Flare Fitting....4037
      Tubelines And Hoses....4037
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....4038
      Specifications....4038
    CONVERSIONS....4040
      Decimal And Millimeter Equivalent Chart....4040
      U.S. To Metric Conversion Chart....4040
    SERVICE TOOLS REQUIRED....4042
      Remote Start Tools....4042
      Hydraulic Tools....4043
      Mainframe And Drive Tools....4045
      Electrical Tools....4046
      Engine Tools....4046
      HVAC Tools....4050
  ALPHABETICAL INDEX....4052
6987172 (12-10) - T650 Compact Track Loader Service Manual....4056
  MAINTENANCE SAFETY....4058
  CONTENTS....4060
  FOREWORD....4062
    FOREWORD....4064
    SAFETY INSTRUCTIONS....4067
    FIRE PREVENTION....4069
      Maintenance....4069
      Operation....4069
      Electrical....4069
      Hydraulic System....4069
      Fueling....4069
      Starting....4069
      Spark Arrestor Exhaust System....4069
      Welding And Grinding....4070
      Fire Extinguishers....4070
    SERIAL NUMBER LOCATIONS....4071
      Loader Serial Number....4071
      Engine Serial Number....4071
    DELIVERY REPORT....4072
    LOADER IDENTIFICATION....4073
  SAFETY & MAINTENANCE....4074
    LIFTING AND BLOCKING THE LOADER....4076
      Procedure....4076
    LIFT ARM SUPPORT DEVICE....4078
      Installing....4078
      Removing....4079
    OPERATOR CAB....4080
      Description....4080
      Raising....4081
      Lowering....4082
      Cab Door Sensor....4083
      Special Applications Kit....4083
      Special Applications Kit Inspection And Maintenance....4083
    TRANSPORTING THE LOADER ON A TRAILER....4084
      Loading And Unloading....4084
      Fastening....4084
    TOWING THE LOADER....4086
      Procedure....4086
    REMOTE START TOOL KIT-MEL1563....4088
      Remote Start Tool - MEL1563....4088
      Service Tool Harness Control - MEL1565....4089
      Service Tool Harness Communicator - MEL1566....4090
      Remote Start Procedure....4090
    REMOTE START TOOL (SERVICE TOOL) KIT - 7003031....4094
      Description....4094
      Remote Start Tool (Service Tool) - 7003030....4095
      Loader Service Tool Harness - 6689747....4096
      Computer Service Tool Harness - 6689746....4097
      Remote Start Procedure....4098
    SERVICE SCHEDULE....4102
      Chart....4102
    AIR CLEANER SERVICE....4104
      Replacing Filter Elements....4104
    ENGINE COOLING SYSTEM....4106
      Maintenance Platform....4106
      Cleaning....4106
      Checking Level....4108
      Removing And Replacing Coolant....4109
    FUEL SYSTEM....4110
      Fuel Specifications....4110
      Biodiesel Blend Fuel....4110
      Filling The Fuel Tank....4111
      Fuel Filter....4112
      Removing Air From The Fuel System....4112
    ENGINE LUBRICATION SYSTEM....4114
      Checking And Adding Engine Oil....4114
      Engine Oil Chart....4114
      Removing And Replacing Oil And Filter....4115
    HYDRAULIC / HYDROSTATIC SYSTEM....4116
      Checking And Adding Fluid....4116
      Hydraulic / Hydrostatic Fluid Chart....4116
      Removing And Replacing Hydraulic Fluid....4117
      Removing And Replacing Hydraulic / Hydrostatic Filter....4119
      Removing And Replacing Hydraulic Charge Filter....4121
      Breather Cap....4122
    BOB-TACH (HAND LEVER)....4124
      Inspection And Maintenance....4124
    BOB-TACH (POWER)....4126
      Inspection And Maintenance....4126
    LUBRICATING THE LOADER....4128
      Lubrication Locations....4128
    SPARK ARRESTOR MUFFLER....4130
      Cleaning Procedure....4130
    PIVOT PINS....4132
      Inspection And Maintenance....4132
    LOADER STORAGE AND RETURN TO SERVICE....4134
      Storage....4134
      Return To Service....4134
    STOPPING THE ENGINE AND LEAVING THE LOADER....4136
      Procedure....4136
    EMERGENCY EXIT....4138
      External Access....4138
      Rear Window....4138
      Front Door....4138
    SEAT BELT....4140
      Inspection And Maintenance....4140
  HYDRAULIC SYSTEM....4142
    HYDRAULIC / HYDROSTATIC SCHEMATICS....4146
    HYDRAULIC SYSTEM INFORMATION....4158
      Glossary Of Hydraulic / Hydrostatic Symbols....4158
      Troubleshooting....4162
    CYLINDER (LIFT)....4164
      Testing....4164
      Removal And Installation....4165
      Parts Identification....4169
      Disassembly....4170
      Assembly....4172
    CYLINDER (TILT)....4176
      Testing....4176
      Removal And Installation....4177
      Base End Pivot Pin Removal And Installation....4179
      Parts Identification....4180
      Disassembly....4181
      Assembly....4183
    CYLINDER (BOB-TACH)....4186
      Testing....4186
      Removal And Installation....4187
      Parts Identification....4188
      Disassembly....4189
      Assembly....4190
    MAIN RELIEF VALVE....4194
      Description....4194
      Testing....4195
      Adjusting....4197
      Removal And Installation....4198
    HYDRAULIC CONTROL VALVE (STANDARD)....4200
      Description....4200
      Removal And Installation....4201
      Mount Bracket Removal And Installation....4204
      Identification Chart....4205
      Lift Load Check Valve Removal And Installation....4206
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....4207
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....4208
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....4208
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....4209
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....4209
      Port Relief Valve Removal And Installation....4210
      Plug Removal And Installation....4211
      Rubber Boot Removal And Installation....4212
      End Cap Block Removal And Installation....4213
      Lift Spool And Detent Removal And Installation....4214
      Tilt Spool Removal And Installation....4224
      Auxiliary Spool Removal And Installation....4226
      Auxiliary Solenoid Removal And Installation....4228
      Solenoid Removal And Installation....4229
      Lock Valve Removal And Installation....4230
      Lift Arm Bypass Orifice Removal And Installation....4232
      Main Relief Valve Removal And Installation....4232
      Check Valve Removal And Installation....4233
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....4234
      Description....4234
      Removal And Installation....4234
      Actuator Removal And Installation (In Loader)....4238
      Actuator Removal And Installation (Out Of Loader)....4240
      Identification Chart....4243
      Mount Bracket Removal And Installation....4244
      Lift Load Check Valve Removal And Installation....4244
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....4245
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....4246
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....4246
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....4247
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....4247
      Port Relief Valve Removal And Installation....4248
      Plug Removal And Installation....4249
      End Cap Block Removal And Installation....4250
      Lift Spool Removal And Installation....4250
      Tilt Spool Removal And Installation....4255
      Auxiliary Spool Removal And Installation....4257
      Auxiliary Solenoid Removal And Installation....4259
      Solenoid Removal And Installation....4260
      Lock Valve Removal And Installation....4261
      Lift Arm Bypass Orifice Removal And Installation....4262
      Main Relief Valve Removal And Installation....4262
      Check Valve Removal And Installation....4263
    LIFT ARM BYPASS CONTROL VALVE....4264
      Description....4264
      Testing....4264
      Removal And Installation....4265
      Bracket Removal And Installation....4266
      Disassembly And Assembly....4266
    HYDRAULIC PUMP....4268
      Description....4268
      Pump Test At Quick Couplers....4268
      Direct Pump Test (Standard Section)....4269
      Direct Pump Test (Charge Section)....4271
      Removal And Installation....4273
      Hydraulic Pump Startup....4274
      Parts Identification....4275
      Disassembly And Assembly....4276
    HYDRAULIC PUMP (HIGH FLOW)....4278
      Description....4278
      Pump Test At Quick Couplers....4278
      Direct Pump Test (Standard Section)....4279
      Direct Pump Test (Charge Section)....4280
      Direct Pump Test (High Flow Section)....4282
      High Flow Relief Valve Adjustment....4284
      High Flow Relief Valve Removal And Installation....4285
      Solenoid Removal And Installation....4286
      Removal And Installation....4287
      Hydraulic Pump Startup....4288
      Parts Identification....4289
      Disassembly And Assembly....4290
    HYDRAULIC / HYDROSTATIC FILTERS....4292
      Description....4292
      Housing Removal And Installation....4292
    HYDRAULIC FLUID RESERVOIR....4294
      Description....4294
      Removal And Installation....4294
      Hydraulic Fluid Screen....4295
    OIL COOLER....4296
      Description....4296
      Removal And Installation....4296
    BUCKET POSITION VALVE....4298
      Description....4298
      Solenoid Removal And Installation....4298
      Solenoid Testing....4299
      Removal And Installation....4299
      Disassembly And Assembly....4301
    REAR AUXILIARY DIVERTER VALVE....4302
      Description....4302
      Solenoid Testing....4302
      Removal And Installation....4303
      Disassembly And Assembly....4304
    BOB-TACH (POWER) BLOCK....4310
      Description....4310
      Removal And Installation....4310
      Disassembly And Assembly....4312
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....4316
      Description....4316
      Removal And Installation....4316
      Disassembly And Assembly....4316
  HYDROSTATIC SYSTEM....4318
    HYDROSTATIC SYSTEM INFORMATION....4320
      Description....4320
      Troubleshooting....4321
    HYDROSTATIC DRIVE MOTOR....4322
      Description....4322
      Removing And Replacing Oil....4322
      Removal And Installation....4323
      Parts Identification....4325
      Disassembly And Assembly....4327
    CHARGE PRESSURE....4340
      Description....4340
      Testing....4340
      Sender Removal And Installation....4342
      Adjusting....4343
    HYDROSTATIC PUMP....4346
      Description....4346
      Removal And Installation....4347
      Hydrostatic Pump Startup....4348
      Replenishing / High Pressure Relief Valve Removal And Installation....4349
      Parts Identification (Left Half)....4350
      Parts Identification (Right Half)....4351
      Disassembly....4352
      Assembly....4359
    HYDROSTATIC PUMP (SJC)....4366
      Description....4366
      Hydraulic Controller Removal And Installation....4367
      Removal And Installation....4369
      Hydrostatic Pump Startup....4371
      Parts Identification....4372
      High Pressure Relief And Bypass Valve....4373
      Charge Relief Valve....4374
      Disassembly And Assembly....4375
      Mechanical Neutral Adjustment....4388
      Hydraulic Controller Neutral Adjustment....4391
    DRIVE BELT....4394
      Belt Adjustment....4394
      Belt Replacement....4394
      Stop Adjustment....4396
      Tensioner Pulley Removal And Installation....4397
      Tensioner Pulley Disassembly And Assembly....4397
    DRAIN MANIFOLD....4400
      Description....4400
      Drain Manifold Removal And Installation....4400
  DRIVE SYSTEM....4402
    BRAKE....4404
      Description....4404
      Block Removal And Installation....4404
      Block Disassembly And Assembly....4405
    TRACK UNDERCARRIAGE COMPONENTS (SOLID- MOUNTED)....4408
      Description....4408
      Checking Tension....4409
      Adjusting Tension....4410
      Track Removal And Installation....4411
      Idler (Front) Removal And Installation....4413
      Track Tensioner Disassembly And Assembly....4416
      Idler (Rear) Removal And Installation....4418
      Roller Removal And Installation....4418
      Sprocket Removal And Installation....4419
      Track Housing Removal And Installation....4420
    TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION)....4422
      Description....4422
      Checking Tension....4423
      Adjusting Tension....4424
      Track Removal And Installation....4425
      Idler (Front) Removal And Installation....4427
      Track Tensioner Disassembly And Assembly....4430
      Idler (Rear) Removal And Installation....4432
      Roller Removal And Installation....4432
      Leaf Spring Removal And Installation....4433
      Sprocket Removal And Installation....4434
      Track Housing Removal And Installation....4435
    TRACK MAINTENANCE....4436
      Track Damage Identification....4436
  MAINFRAME....4448
    SEAT BAR....4452
      Description....4452
      Removal And Installation....4452
      Disassembly And Assembly....4453
      Compression Spring Disassembly And Assembly....4454
    OPERATOR CAB....4456
      Gas Spring Removal And Installation....4456
      Gas Spring Bracket Disassembly And Assembly....4457
      Removal And Installation....4457
    OPERATOR SEAT (SUSPENSION)....4460
      Removal And Installation....4460
      Slide Rail Removal And Installation....4460
      Seat Belt Removal And Installation....4461
      Lower Cushion Removal....4461
      Lower Cushion Installation....4462
      Back Cushion Removal And Installation....4462
      Shock Removal And Installation....4463
      3-Point Seat Belt Removal And Installation....4463
    BOB-TACH (HAND LEVER)....4466
      Description....4466
      Removal And Installation....4466
      Lever And Wedge Disassembly And Assembly....4468
      Pivot Pin Bushing And Seal Removal And Installation....4470
    BOB-TACH (POWER)....4472
      Description....4472
      Removal And Installation....4472
      Lever And Wedge Disassembly And Assembly....4475
      Pivot Pin Bushing And Seal Removal And Installation....4476
    LIFT ARMS....4478
      Stabilizer Bar Removal And Installation....4478
      Link Removal And Installation....4479
      Removal And Installation....4480
    REAR GRILLE....4484
      Removal And Installation....4484
    REAR DOOR (TAILGATE)....4486
      Removal And Installation....4486
      Striker Removal And Installation....4487
      Striker Disassembly And Assembly....4487
      Striker (Adjusting)....4487
      Latch Removal And Installation....4488
    FUEL TANK....4490
      Removal And Installation....4490
      Fuel Level Sender Removal And Installation....4492
      Fuel Fill Screen Removal And Installation....4492
    CONTROL PEDALS AND LINKAGES....4494
      Description....4494
      Pedal Removal And Installation....4494
      Linkage Removal And Installation....4495
      Pedal (Adjusting)....4496
      Floor Pan Removal And Installation....4497
    CONTROL PEDALS AND LINKAGES (ACS)....4498
      Description....4498
      Pedal Removal And Installation....4498
      Linkage Removal And Installation....4499
      Pedal (Adjusting)....4499
      Floor Pan Removal And Installation....4500
    CONTROL PANEL....4502
      Description....4502
      Removal And Installation....4503
      Disassembly And Assembly....4504
      Linkage Removal And Installation....4506
      Pintle Arm Disassembly And Assembly....4510
      Linkage Neutral (Adjusting)....4511
      Linkage Travel (Adjusting)....4515
      Shock Removal And Installation....4519
    CONTROL PANEL (SJC)....4520
      Description....4520
      Removal And Installation....4520
    CONTROL HANDLE / LEVER....4522
      Description....4522
      Lever Removal And Installation....4522
      Boot Removal And Installation....4523
    CONTROL HANDLE / LEVER (ACS)....4524
      Description....4524
      Handle Sensor Removal And Installation....4524
      Handle Removal And Installation....4527
      Handle Disassembly And Assembly....4528
      Lever Removal And Installation....4528
      Boot Removal And Installation....4529
    CONTROL HANDLE / LEVER (SJC)....4530
      Description....4530
      Joystick Testing....4530
      Joystick Removal And Installation....4531
    ACCESS PANEL (INSIDE)....4532
      Removal And Installation (Left)....4532
      Removal And Installation (Right)....4532
    ACCESS PANEL (INSIDE) (SJC)....4534
      Removal And Installation (Left)....4534
      Removal And Installation (Right)....4534
    WINDOW (REAR)....4536
      Removal And Installation....4536
      Disassembly And Assembly....4536
    WINDOW (TOP)....4538
      Removal And Installation....4538
    WINDOW (SIDE)....4540
      Removal And Installation....4540
    CAB DOOR....4542
      Description....4542
      Removal And Installation....4542
      Disassembly And Assembly....4543
      Aligning....4544
      Adjusting....4545
      Checking Operation....4545
    ARMREST....4546
      Description....4546
      Removal And Installation....4547
      Disassembly And Assembly....4548
    LEFT SIDE LOWER PANEL....4550
      Removal And Installation....4550
      Disassembly And Assembly....4552
    RIGHT SIDE LOWER PANEL....4554
      Removal And Installation....4554
      Disassembly And Assembly....4555
    HEADLINER....4558
      Removal And Installation....4558
  ELECTRICAL SYSTEM & ANALYSIS....4560
    ELECTRICAL SCHEMATICS....4564
    ELECTRICAL SYSTEM INFORMATION....4620
      Glossary Of Electrical Symbols....4620
      Standard Cab Harness Connectors....4623
      Deluxe Cab Harness Connectors....4624
      Mainframe Harness Connectors....4625
      Description....4626
      Troubleshooting....4627
      Fuse And Relay Location / Identification....4628
      Solenoid Testing....4630
    BATTERY....4632
      Removal And Installation....4632
      Servicing....4633
      Using A Booster Battery (Jump Starting)....4634
    ALTERNATOR....4636
      Belt Adjustment....4636
      Belt Replacement....4636
      Charging System Inspection....4637
      Alternator Voltage Testing....4638
      Low Voltage Testing....4638
      High Voltage Testing....4639
      Removal And Installation....4640
      Parts Identification....4641
    STARTER....4642
      Testing....4642
      Removal And Installation....4642
      Parts Identification....4643
    INSTRUMENT PANELS....4644
      Left Panel....4644
      Display Screen....4646
      Right Panel (Standard Key Panel)....4647
      Right Panel (Keyless Start Panel)....4648
      Right Panel (Deluxe Instrumentation Panel)....4649
      Left Switch Panel....4651
      Right Switch Panel....4651
      Left Panel Removal And Installation....4652
      Right Panel (Standard Key Panel) Removal And Installation....4652
      Right Panel (Keyless Start Panel) Removal And Installation....4653
      Right Panel (Deluxe Instrumentation Panel) Removal And Installation....4653
      Key Switch Disassembly And Assembly....4654
      Alarm Disassembly And Assembly....4654
      Left Switch Panel Removal And Installation....4655
      Right Switch Panel Removal And Installation....4655
    LIGHTS....4656
      Front Removal And Installation....4656
      Rear Removal And Installation....4657
      Cab Light Removal And Installation....4657
    BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)....4658
      Description....4658
      Connector Identification....4659
      Removal And Installation....4665
    BOBCAT CONTROLLER (ACS)....4666
      Description....4666
      Connector And Wire Identification....4667
      Removal And Installation....4668
    BOBCAT CONTROLLER (SJC) (DRIVE)....4670
      Description....4670
      Connector Identification....4671
      Removal And Installation....4673
    SPEED SENSORS (SJC)....4674
      Description....4674
      Testing....4674
      Removal And Installation....4675
    DIAGNOSTIC SERVICE CODES....4678
      Viewing Service Codes....4678
      Service Codes List....4679
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....4684
      Description....4684
      Inspecting The BICS (Engine STOPPED - Key ON)....4685
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....4685
      Inspecting The Seat Bar Sensor (Engine RUNNING)....4685
      Inspecting The Traction Lock (Engine RUNNING)....4685
      Inspecting The Lift Arm Bypass Control....4685
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....4685
      Troubleshooting....4686
    SEAT BAR SENSOR....4688
      Description....4688
      Troubleshooting....4688
      Testing....4689
      Removal And Installation....4690
      Bobcat Interlock Control System (BICS) Circuit Test....4691
    TRACTION LOCK....4694
      Description....4694
      Troubleshooting....4695
      Inspecting....4696
    CONTROL SYSTEM (ACS)....4698
      Description....4698
      Troubleshooting....4699
      Handle Sensor Connector Disassembly And Assembly....4700
      Switch Handle Removal....4701
      Switch Handle Installation....4703
      Actuator Connector Disassembly And Assembly....4706
      Handle Lock Solenoid Removal And Installation....4707
      Handle Lock Solenoid Disassembly And Assembly....4707
      Foot Sensor Removal And Installation....4708
      Foot Sensor Disassembly And Assembly....4709
      Foot Sensor Lock Solenoid Removal And Installation....4709
    ELECTRICAL / HYDRAULIC CONTROLS....4710
      Identification Chart....4710
      Description....4711
      Identification Chart ACD Group 0....4712
      Identification Chart ACD Group 1....4713
      Identification Chart ACD Group 2....4714
      Identification Chart ACD Group 3....4715
    ELECTRICAL / HYDRAULIC CONTROLS (ACS)....4716
      Identification Chart....4716
      Description....4717
      Identification Chart ACD Group 0....4718
      Identification Chart ACD Group 1....4719
      Identification Chart ACD Group 2....4720
      Identification Chart ACD Group 3....4721
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)....4722
      Identification Chart....4722
      Description....4723
      Identification Chart ACD Group 0....4724
      Identification Chart ACD Group 1....4725
      Identification Chart ACD Group 2....4726
      Identification Chart ACD Group 3....4727
    SERVICE PC (LAPTOP COMPUTER)....4728
      Connecting Remote Start Tool....4728
      Connecting Remote Start Tool (Service Tool)....4728
    CALIBRATION....4730
      Description....4730
      Actuator Testing....4730
      Lift And Tilt Calibration (SJC)....4733
      Hydrostatic Pump Calibration (SJC)....4735
      Lift And Tilt Calibration (ACS)....4740
    STEERING DRIFT COMPENSATION....4742
      Description....4742
      Operation....4742
    FLYWHEEL RPM SENSOR....4744
      Description....4744
      Adjustment....4745
    CONTROL PANEL SETUP....4746
      Right Panel Setup (Deluxe Instrumentation Panel)....4746
      Attachment Control Information (Deluxe Instrumentation Panel)....4747
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....4748
      Password Description....4748
      Changing The Owner Password....4748
      Changing The User Passwords....4749
      Password Lockout Feature....4749
    PASSWORD SETUP (KEYLESS START PANEL)....4750
      Password Description....4750
      Changing The Owner Password....4750
      Password Lockout Feature....4750
    MAINTENANCE CLOCK....4752
      Description....4752
      Setup....4753
      Reset....4756
    BACK-UP ALARM SYSTEM....4758
      Description....4758
      Inspecting....4758
      Adjusting Switch Position....4759
      Troubleshooting (Standard And ACS)....4760
      Troubleshooting (Joystick)....4761
      Alarm Removal And Installation....4762
      Switch Removal And Installation....4762
    FRONT HORN....4764
      Removal And Installation....4764
  ENGINE SERVICE....4766
    ENGINE INFORMATION....4770
      Description....4770
      Specifications....4771
      Torque Values....4774
      Troubleshooting....4774
      Engine Removal And Installation....4776
      Engine Mount Replacement....4783
      Compression - Checking....4784
    ENGINE SPEED CONTROL....4786
      Removal And Installation....4786
      Disassembly And Assembly....4786
      Cable Removal And Installation....4787
    ENGINE SPEED CONTROL (SJC) S/N A3P011522 & BELOW AND S/N A3P111118 & BELOW....4788
      Removal And Installation....4788
      Disassembly And Assembly....4789
    ENGINE SPEED CONTROL (SJC) S/N A3P011523 & ABOVE AND S/N A3P111119 & ABOVE....4792
      Removal And Installation....4792
      Disassembly And Assembly....4793
    MUFFLER....4796
      Removal And Installation....4796
    AIR CLEANER....4798
      Housing Removal And Installation....4798
      Housing Bracket Removal And Installation....4799
    ENGINE COOLING SYSTEM....4800
      Radiator Removal And Installation....4800
      Hydraulic Fan Description....4802
      Hydraulic Fan Disassembly And Assembly....4803
      Lower Fan Duct Removal And Installation....4804
      Blower Housing Removal And Installation....4804
      Hydraulic Fan Motor Assembly Removal And Installation....4805
      Fan Removal And Installation....4805
      Hydraulic Fan Motor Removal And Installation....4806
      Water Pump Removal And Installation....4807
      Water Pump Disassembly And Assembly....4807
      Thermostat Housing Removal And Installation....4808
      Thermostat - Checking....4809
    LUBRICATION SYSTEM....4810
      Oil Pan Removal And Installation....4810
      Oil Pump Removal And Installation....4810
      Relief Valve - Testing....4811
      Oil Pump Inspection....4811
      Oil Filter Cooler Removal And Installation....4812
      Engine Oil Pressure - Testing....4813
    FUEL SYSTEM....4814
      Fuel Shutoff Solenoid - Checking....4814
      Fuel Shutoff Solenoid Removal And Installation....4814
      Fuel Injection Pump - Checking....4815
      Fuel Injection Pump Assembly Removal And Installation....4816
      Governor Housing Disassembly And Assembly....4819
      Governor Disassembly And Assembly....4821
      Fuel Camshaft Removal And Installation....4823
      Fuel Injection Pump Removal And Installation....4825
      Fuel Injection Pump - Timing....4827
      Fuel Injector Removal And Installation....4828
      Fuel Injector Nozzle Pressure - Checking....4830
      Nozzle Spray Condition....4831
      Valve Seat Tightness....4831
    CYLINDER HEAD....4832
      Glow Plugs - Testing....4832
      Glow Plugs Removal And Installation....4832
      Valve Clearance Adjustment....4833
      Valve Timing - Checking....4834
      Cylinder Head Removal And Installation....4835
      Cylinder Head Disassembly And Assembly....4838
      Cylinder Head - Servicing....4838
      Cylinder Head Top Clearance....4839
      Valve Guide - Checking....4839
      Valve Guide Removal And Installation....4840
      Reconditioning The Valve And Valve Seat....4840
      Valve Spring....4842
      Valve Tappets....4843
      Rocker Arm And Shaft - Checking....4844
      Bridge Arm And Bridge Arm Shaft - Checking....4844
      Bridge Arm Shaft - Removal And Installation....4845
      Push Rod Alignment - Checking....4846
    CRANKSHAFT AND PISTONS....4848
      Piston And Connecting Rod Removal And Installation....4848
      Piston And Connecting Rod - Servicing....4849
      Cylinder Bore - Checking....4852
      Connecting Rod Alignment....4853
      Crankshaft Gear Removal And Installation....4853
      Crankshaft And Bearings Removal And Installation....4854
      Crankshaft And Bearings - Servicing....4856
    CAMSHAFT AND TIMING GEARS....4860
      Timing Gearcase Cover Removal....4860
      Timing Gearcase Cover Installation....4861
      Timing Gears Backlash - Checking....4864
      Idler Gear And Camshaft Removal And Installation....4864
      Camshaft - Servicing....4865
      Idler Gear And Shaft - Servicing....4866
    TURBOCHARGER....4868
      Description....4868
      Testing....4868
      Removal And Installation....4869
    FLYWHEEL AND HOUSING....4872
      Flywheel Removal And Installation....4872
      Ring Gear Removal And Installation....4874
      Housing Removal And Installation....4874
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM....4876
      Description....4876
      Testing....4877
      Removal And Installation....4880
      Disassembly And Assembly....4881
  HEATING, VENTILATION, AIR CONDITIONING....4882
    AIR CONDITIONING SYSTEM FLOW....4885
      Description....4885
      Chart....4886
      Components....4887
      Safety Equipment....4890
    REGULAR MAINTENANCE....4892
      Filters....4892
      Compressor Drive Belt Adjustment....4893
      Compressor Drive Belt Replacement....4893
      Condenser....4893
      Air Conditioning Lubrication....4893
      Air Conditioning Service Chart....4894
      Evaporator / Heater Coil....4895
    TROUBLESHOOTING....4896
      Blower Motor Does Not Operate....4896
      Blower Motor Operates Normally, But Air Flow Is Insufficient....4896
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....4896
      The Compressor Does Not Operate At All, Or Operates Improperly....4896
      Gauge Pressure Related Troubleshooting....4897
      Troubleshooting Tree....4899
      Temperature / Pressure Chart....4903
      Poor A/C Performance....4905
      HVAC Repair And Leaks....4906
      Electrical System....4907
      Engine Coolant Bypassing The Heater Valve....4913
      Heater Valve Not Opening Or Closing....4914
    SYSTEM CHARGING AND RECLAMATION....4916
      Refrigerant Identification....4916
      Reclamation And Charging With Recovery / Charging Unit....4917
    COMPRESSOR....4920
      Removal And Installation....4920
      Oil....4921
      Oil Check....4922
    CONDENSER....4924
      Removal And Installation....4924
    RECEIVER / DRIER....4926
      Receiver / Drier Removal And Installation....4926
      Pressure Relief Valve Removal And Installation....4927
      Pressure Switch Removal And Installation....4928
      Schraeder Valve Removal And Installation....4929
    EVAPORATOR / HEATER UNIT....4930
      Removal And Installation....4930
    THERMOSTAT....4932
      Description....4932
      Removal And Installation....4933
    EXPANSION VALVE....4934
      Removal And Installation....4934
    EVAPORATOR COIL....4936
      Removal And Installation....4936
    HEATER COIL....4938
      Removal And Installation....4938
    BLOWER FAN....4940
      Removal And Installation....4940
      Disassembly And Assembly....4940
    HEATER VALVE....4944
      Removal And Installation....4944
  SPECIFICATIONS....4946
    (T650) LOADER SPECIFICATIONS....4948
      Machine Dimensions....4948
      Performance....4949
      Engine....4949
      Drive System....4949
      Controls....4950
      Hydraulic System....4950
      Electrical System....4951
      Capacities....4951
      Tracks....4951
      Ground Pressure....4951
    TORQUE SPECIFICATIONS FOR BOLTS....4952
      Torque For General SAE Bolts....4952
      Torque For General Metric Bolts....4953
    HYDRAULIC CONNECTION SPECIFICATIONS....4954
      Straight Thread O-ring Fitting....4954
      Flare Fitting....4955
      Tubelines And Hoses....4955
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....4956
      Specifications....4956
    CONVERSIONS....4958
      Decimal And Millimeter Equivalent Chart....4958
      U.S. To Metric Conversion Chart....4958
  ALPHABETICAL INDEX....4960
  SERVICE MANUAL REVISION....4964
    Revision No: T650 - 1....4964
    Revision No: T650 - 2....4966
    Revision No: T650 - 3....4968
    Revision No: T650 - 4....4970
    Revision No: T650 - 5....4972
    Revision No: T650 - 6....4974
    Revision No: T650 - 7....4976
6989679 (08-12) - T550 Compact Track Loader Service Manual....4978
  MAINTENANCE SAFETY....4980
  CONTENTS....4982
  FOREWORD....4984
    FOREWORD....4986
    SAFETY INSTRUCTIONS....4988
    FIRE PREVENTION....4990
      Maintenance....4990
      Operation....4990
      Electrical....4990
      Hydraulic System....4990
      Fueling....4990
      Starting....4990
      Spark Arrester Exhaust System....4990
      Welding And Grinding....4991
      Fire Extinguishers....4991
    SERIAL NUMBER LOCATIONS....4992
      Loader Serial Number....4992
      Engine Serial Number....4992
    DELIVERY REPORT....4993
    LOADER IDENTIFICATION....4994
  SAFETY AND MAINTENANCE....4996
    LIFTING AND BLOCKING THE LOADER....4998
      Procedure....4998
    LIFT ARM SUPPORT DEVICE....5000
      Description....5000
      Installing....5001
      Removing....5002
    OPERATOR CAB....5004
      Description....5004
      Raising....5005
      Lowering....5006
      Cab Door Sensor....5007
      Special Applications Kit....5007
      Special Applications Kit Inspection And Maintenance....5007
      Forestry Door And Window Kit....5008
      Forestry Door And Window Kit Inspection And Maintenance....5008
    TRANSPORTING THE LOADER ON A TRAILER....5010
      Loading And Unloading....5010
      Fastening....5010
    TOWING THE LOADER....5012
      Procedure....5012
    REMOTE START TOOL KIT- MEL1563....5014
      Remote Start Tool - MEL1563....5014
      Service Tool Harness Communicator - MEL1566....5016
      Remote Start Procedure....5016
    REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....5020
      Description....5020
      Remote Start Tool (Service Tool) - 7022042....5021
      Loader Service Tool Harness - 6689747....5022
      Computer Service Tool Harness - 6689746....5023
      Remote Start Procedure....5024
    SERVICE SCHEDULE....5028
      Maintenance Intervals....5028
    ENGINE AIR CLEANER....5030
      Replacing Filters....5030
    ENGINE COOLING SYSTEM....5032
      Maintenance Platform....5032
      Cleaning....5032
      Checking And Adding Coolant....5034
      Removing And Replacing Coolant....5035
    FUEL SYSTEM....5036
      Fuel Specifications....5036
      Biodiesel Blend Fuel....5036
      Filling The Fuel Tank....5037
      Fuel Filter....5038
      Removing Air From The Fuel System....5039
    ENGINE LUBRICATION SYSTEM....5040
      Checking And Adding Engine Oil....5040
      Engine Oil Chart....5040
      Removing And Replacing Oil And Filter....5041
    HYDRAULIC / HYDROSTATIC SYSTEM....5042
      Checking And Adding Fluid....5042
      Hydraulic / Hydrostatic Fluid Chart....5042
      Removing And Replacing Hydraulic Fluid....5043
      Removing And Replacing Hydraulic / Hydrostatic Filter....5045
      Removing And Replacing Hydraulic Charge Filter....5046
      Replacing Reservoir Breather Cap....5047
    BOB-TACH (HAND LEVER)....5048
      Inspection And Maintenance....5048
    BOB-TACH (POWER)....5050
      Inspection And Maintenance....5050
    LUBRICATING THE LOADER....5052
      Lubrication Locations....5052
    SPARK ARRESTER MUFFLER....5056
      Cleaning Procedure....5056
    PIVOT PINS....5058
      Inspection And Maintenance....5058
    LOADER STORAGE AND RETURN TO SERVICE....5060
      Storage....5060
      Return To Service....5060
    STOPPING THE ENGINE AND LEAVING THE LOADER....5062
      Procedure....5062
    EMERGENCY EXIT....5064
      Rear Window....5064
      External Access....5064
      Front Door....5065
    SEAT BELT....5068
      Inspection And Maintenance....5068
  HYDRAULIC SYSTEM....5070
    HYDRAULIC / HYDROSTATIC SCHEMATICS....5074
    HYDRAULIC SYSTEM INFORMATION....5082
      Glossary Of Hydraulic / Hydrostatic Symbols....5082
      Troubleshooting....5086
    CYLINDER (LIFT)....5088
      Testing....5088
      Removal And Installation....5089
      Parts Identification....5092
      Disassembly....5093
      Assembly....5095
    CYLINDER (TILT)....5100
      Testing....5100
      Removal And Installation....5101
      Base End Pivot Pin Removal And Installation....5102
      Parts Identification....5103
      Disassembly....5104
      Assembly....5106
    CYLINDER (BOB-TACH)....5110
      Testing....5110
      Removal And Installation....5111
      Parts Identification....5112
      Disassembly....5113
      Assembly....5115
    MAIN RELIEF VALVE....5118
      Description....5118
      Testing....5119
      Adjusting....5121
      Removal And Installation....5122
    HYDRAULIC CONTROL VALVE (STANDARD)....5124
      Description....5124
      Removal And Installation....5125
      Mount Bracket Removal And Installation....5128
      Identification Chart....5129
      Lift Load Check Valve Removal And Installation....5130
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....5131
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....5132
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....5132
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....5133
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....5133
      Port Relief Valve Removal And Installation....5134
      Plug Removal And Installation....5136
      Rubber Boot Removal And Installation....5137
      End Cap Block Removal And Installation....5137
      Lift Spool And Detent Removal And Installation....5138
      Tilt Spool Removal And Installation....5146
      Auxiliary Spool Removal And Installation....5148
      Auxiliary Solenoid Removal And Installation....5149
      Solenoid Removal And Installation....5150
      Lock Valve Removal And Installation....5151
      Lift Arm Bypass Orifice Removal And Installation....5153
      Main Relief Valve Removal And Installation....5153
      Check Valve Removal And Installation....5154
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....5156
      Description....5156
      Removal And Installation....5156
      Actuator Removal And Installation (In Loader)....5160
      Actuator Removal And Installation (Out Of Loader)....5162
      Identification Chart....5165
      Mount Bracket Removal And Installation....5166
      Lift Load Check Valve Removal And Installation....5166
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....5167
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....5168
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....5168
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....5169
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....5169
      Port Relief Valve Removal And Installation....5170
      Plug Removal And Installation....5172
      End Cap Block Removal And Installation....5173
      Lift Spool Removal And Installation....5173
      Lift Spool Disassembly And Assembly....5175
      Tilt Spool Removal And Installation....5176
      Auxiliary Spool Removal And Installation....5178
      Auxiliary Solenoid Removal And Installation....5179
      Solenoid Removal And Installation....5180
      Lock Valve Removal And Installation....5181
      Lift Arm Bypass Orifice Removal And Installation....5183
      Main Relief Valve Removal And Installation....5183
      Check Valve Removal And Installation....5184
    LIFT ARM BYPASS CONTROL VALVE....5186
      Description....5186
      Testing....5186
      Removal And Installation....5187
      Bracket Removal And Installation....5188
      Disassembly And Assembly....5188
    HYDRAULIC PUMP....5190
      Description....5190
      Pump Test At Quick Couplers....5191
      Direct Pump Test (Standard Section)....5193
      Direct Pump Test (Charge Section)....5195
      Removal And Installation....5197
      Hydraulic Pump Startup....5199
      Parts Identification....5200
      Disassembly And Assembly....5201
    HYDRAULIC PUMP (HIGH FLOW)....5202
      Description....5202
      Pump Test At Quick Couplers....5203
      Direct Pump Test (Standard Section)....5205
      Direct Pump Test (Charge Section)....5206
      Direct Pump Test (High Flow Section)....5208
      High Flow Relief Valve Adjustment....5210
      High Flow Relief Valve Removal And Installation....5211
      Solenoid Removal And Installation....5212
      Removal And Installation....5213
      Hydraulic Pump Startup....5215
      Parts Identification....5216
      Disassembly And Assembly....5217
    HYDRAULIC / HYDROSTATIC FILTERS....5218
      Description....5218
      Housing Removal And Installation....5218
    HYDRAULIC FLUID RESERVOIR....5220
      Description....5220
      Removal And Installation....5220
      Hydraulic Fluid Screen....5221
    OIL COOLER....5222
      Description....5222
      Removal And Installation....5222
    BUCKET POSITION VALVE....5224
      Description....5224
      Solenoid Removal And Installation....5224
      Solenoid Testing....5225
      Removal And Installation....5226
      Disassembly And Assembly....5228
    REAR AUXILIARY DIVERTER VALVE....5230
      Description....5230
      Solenoid Testing....5230
      Removal And Installation....5231
      Disassembly And Assembly....5232
    BOB-TACH (POWER) BLOCK....5238
      Description....5238
      Removal And Installation....5238
      Disassembly And Assembly....5240
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....5248
      Description....5248
      Removal And Installation....5248
      Disassembly And Assembly....5248
  HYDROSTATIC SYSTEM....5250
    HYDROSTATIC SYSTEM INFORMATION....5252
      Description....5252
      Troubleshooting....5253
    HYDROSTATIC DRIVE MOTOR....5254
      Description....5254
      Removing And Replacing Oil....5255
      Removal And Installation....5257
      Parts Identification....5259
      Disassembly....5261
      Assembly....5269
    CHARGE PRESSURE....5278
      Description....5278
      Testing....5279
      Adjusting....5280
      Sender Removal And Installation....5282
    HYDROSTATIC PUMP....5284
      Description....5284
      Removal And Installation....5285
      Hydrostatic Pump Startup....5286
      Replenishing / High Pressure Relief Valve Removal And Installation....5287
      Parts Identification (Left Half)....5288
      Parts Identification (Right Half)....5289
      Disassembly....5290
      Assembly....5297
    HYDROSTATIC PUMP (SJC)....5304
      Description....5304
      Hydraulic Controller Removal And Installation....5305
      Removal And Installation....5307
      Hydrostatic Pump Startup....5309
      Parts Identification....5310
      High Pressure Relief And Bypass Valve....5311
      Charge Relief Valve....5312
      Disassembly And Assembly....5313
      Mechanical Neutral Adjustment....5326
      Hydraulic Controller Neutral Adjustment....5329
    DRIVE BELT....5332
      Belt Adjustment....5332
      Belt Replacement....5333
    DRAIN MANIFOLD....5336
      Description....5336
      Drain Manifold Removal And Installation....5336
  DRIVE SYSTEM....5338
    BRAKE....5340
      Description....5340
      Block Removal And Installation....5340
      Block Disassembly And Assembly....5342
    TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED)....5344
      Description....5344
      Checking Tension....5345
      Adjusting Tension....5346
      Track Removal And Installation....5347
      Idler (Front) Removal And Installation....5349
      Track Tensioner Disassembly And Assembly....5352
      Idler (Rear) Removal And Installation....5354
      Roller Removal And Installation....5354
      Sprocket Removal And Installation....5355
      Track Housing Removal And Installation....5356
    TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION)....5358
      Description....5358
      Checking Tension....5359
      Adjusting Tension....5360
      Track Removal And Installation....5361
      Idler (Front) Removal And Installation....5363
      Track Tensioner Disassembly And Assembly....5366
      Idler (Rear) Removal And Installation....5368
      Leaf Spring Removal And Installation....5369
      Sprocket Removal And Installation....5370
      Track Housing Removal And Installation....5371
    TRACK MAINTENANCE....5374
      Track Damage Identification....5374
  MAINFRAME....5386
    SEAT BAR....5390
      Description....5390
      Removal And Installation....5390
      Disassembly And Assembly....5391
      Compression Spring Disassembly And Assembly....5392
    OPERATOR CAB....5394
      Gas Spring Removal And Installation....5394
      Gas Spring Bracket Disassembly And Assembly....5395
      Removal And Installation....5395
    OPERATOR SEAT (SUSPENSION)....5398
      Removal And Installation....5398
      Slide Rail Removal And Installation....5398
      Seat Belt Removal And Installation....5399
      Lower Cushion Removal....5399
      Lower Cushion Installation....5400
      Back Cushion Removal And Installation....5400
      Shock Removal And Installation....5401
      3-Point Seat Belt Removal And Installation....5401
    BOB-TACH (HAND LEVER)....5404
      Description....5404
      Removal And Installation....5404
      Lever And Wedge Disassembly And Assembly....5406
      Pivot Pin Bushing And Seal Removal And Installation....5408
    BOB-TACH (POWER)....5410
      Description....5410
      Removal And Installation....5410
      Lever And Wedge Disassembly And Assembly....5413
      Pivot Pin Bushing And Seal Removal And Installation....5414
    LIFT ARMS....5416
      Removal And Installation....5416
    REAR GRILLE....5418
      Removing....5418
      Installing....5418
    REAR DOOR (TAILGATE)....5420
      Removal And Installation....5420
      Striker Removal And Installation....5421
      Striker Disassembly And Assembly....5421
      Striker (Adjusting)....5422
      Latch Removal And Installation....5422
    FUEL TANK....5424
      Removal And Installation....5424
      Fuel Level Sender Removal And Installation....5426
      Fuel Fill Screen Removal And Installation....5427
    CONTROL PEDALS AND LINKAGES....5428
      Description....5428
      Pedal Removal And Installation....5428
      Linkage Removal And Installation....5429
      Pedal (Adjusting)....5430
      Floor Pan Removal And Installation....5431
    CONTROL PEDALS AND LINKAGES (ACS)....5432
      Description....5432
      Pedal Removal And Installation....5432
      Linkage Removal And Installation....5433
      Pedal (Adjusting)....5433
      Floor Pan Removal And Installation....5434
    CONTROL PANEL....5436
      Description....5436
      Removal And Installation....5437
      Disassembly And Assembly....5438
      Linkage Removal And Installation....5440
      Pintle Arm Disassembly And Assembly....5444
      Linkage Neutral (Adjusting)....5445
      Linkage Travel (Adjusting)....5449
      Shock Removal And Installation....5453
    CONTROL PANEL (SJC)....5454
      Description....5454
      Removal And Installation....5454
    CONTROL HANDLE / LEVER....5456
      Description....5456
      Lever Removal And Installation....5456
      Boot Removal And Installation....5457
    CONTROL HANDLE / LEVER (ACS)....5458
      Description....5458
      Handle Sensor Removal And Installation....5458
      Handle Removal And Installation....5461
      Handle Disassembly And Assembly....5462
      Lever Removal And Installation....5462
      Boot Removal And Installation....5463
    CONTROL HANDLE / LEVER (SJC)....5464
      Description....5464
      Joystick Testing....5464
      Joystick Removal And Installation....5465
    ACCESS PANEL (INSIDE)....5466
      Removal And Installation (Left)....5466
      Removal And Installation (Right)....5466
    ACCESS PANEL (INSIDE) (SJC)....5468
      Removal And Installation (Left)....5468
      Removal And Installation (Right)....5468
    WINDOW (REAR)....5470
      Removal And Installation....5470
      Disassembly And Assembly....5470
    WINDOW (TOP)....5472
      Removal And Installation....5472
    WINDOW (SIDE)....5474
      Removal And Installation....5474
    CAB DOOR....5476
      Description....5476
      Removal And Installation....5476
      Disassembly And Assembly....5477
      Aligning....5478
      Adjusting....5479
      Checking Operation....5479
    ARMREST....5480
      Description....5480
      Removal And Installation....5481
      Disassembly And Assembly....5482
    LEFT SIDE LOWER PANEL....5484
      Removal And Installation....5484
      Disassembly And Assembly....5486
    RIGHT SIDE LOWER PANEL....5488
      Removal And Installation....5488
      Disassembly And Assembly....5489
    HEADLINER....5492
      Removal And Installation....5492
  ELECTRICAL SYSTEM AND ANALYSIS....5494
    ELECTRICAL SCHEMATICS....5500
    ELECTRICAL SYSTEM INFORMATION....5532
      Glossary Of Electrical Symbols....5532
      Standard Cab Harness Connectors....5535
      Deluxe Cab Harness Connectors....5536
      Mainframe Harness Connectors - Manual Controls....5537
      Mainframe Harness Connectors - SJC....5538
      Description....5539
      Troubleshooting....5540
      Fuse And Relay Location / Identification....5541
      Solenoid Testing....5543
    BATTERY....5544
      Removal And Installation....5544
      Servicing....5545
      Using A Booster Battery (Jump Starting)....5546
    ALTERNATOR....5548
      Belt Adjustment....5548
      Belt Replacement....5548
      Charging System Inspection....5549
      Alternator Voltage Testing....5550
      Low Voltage Testing....5550
      High Voltage Testing....5551
      Removal And Installation....5552
      Parts Identification....5554
    STARTER....5556
      Testing....5556
      Removal And Installation....5556
      Parts Identification....5557
    INSTRUMENT PANELS....5558
      Left Panel....5558
      Display Screen....5560
      Right Panel (Standard Key Panel)....5561
      Right Panel (Keyless Start Panel)....5562
      Right Panel (Deluxe Instrumentation Panel)....5563
      Left Switch Panel....5565
      Right Switch Panel....5565
      Left Side Lower Panel....5566
      Right Side Lower Panel....5566
      Left Panel Removal And Installation....5567
      Right Panel (Standard Key Panel) Removal And Installation....5567
      Right Panel (Keyless Start Panel) Removal And Installation....5568
      Right Panel (Deluxe Instrumentation Panel) Removal And Installation....5568
      Key Switch Disassembly And Assembly....5569
      Alarm Disassembly And Assembly....5569
      Left Switch Panel Removal And Installation....5570
      Right Switch Panel Removal And Installation....5570
    LIGHTS....5572
      Front Removal And Installation....5572
      Rear Removal And Installation....5573
      Cab Light Removal And Installation....5573
    BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)....5574
      Description....5574
      Connector Identification....5575
      Removal And Installation....5581
    BOBCAT CONTROLLER (ACS)....5582
      Description....5582
      Connector And Wire Identification....5583
      Removal And Installation....5584
    BOBCAT CONTROLLER (SJC) (DRIVE)....5586
      Description....5586
      Connector Identification....5587
      Removal And Installation....5589
    DIAGNOSTIC SERVICE CODES....5590
      Viewing Service Codes....5590
      Service Codes List....5591
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....5598
      Description....5598
      Inspecting The BICS (Engine STOPPED - Key ON)....5599
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....5599
      Inspecting The Seat Bar Sensor (Engine RUNNING)....5599
      Inspecting The Traction Lock (Engine RUNNING)....5599
      Inspecting The Lift Arm Bypass Control....5599
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....5599
      Troubleshooting....5600
    SEAT BAR SENSOR....5602
      Description....5602
      Troubleshooting....5602
      Testing....5603
      Removal....5604
      Installation....5606
      Bobcat Interlock Control System (BICS) Circuit Test....5607
    TRACTION LOCK....5610
      Description....5610
      Troubleshooting....5611
      Inspecting....5612
    CONTROL SYSTEM (ACS)....5614
      Description....5614
      Troubleshooting....5615
      Handle Sensor Connector Disassembly And Assembly....5616
      Switch Handle Removal....5617
      Switch Handle Installation....5619
      Actuator Connector Disassembly And Assembly....5622
      Handle Lock Solenoid Removal And Installation....5623
      Handle Lock Solenoid Disassembly And Assembly....5623
      Foot Sensor Removal And Installation....5624
      Foot Sensor Disassembly And Assembly....5625
      Foot Sensor Lock Solenoid Removal And Installation....5625
    ELECTRICAL / HYDRAULIC CONTROLS....5626
      Identification Chart....5626
      Description....5627
      Identification Chart ACD Group 0....5628
      Identification Chart ACD Group 1....5629
      Identification Chart ACD Group 2....5630
      Identification Chart ACD Group 3....5631
    ELECTRICAL / HYDRAULIC CONTROLS (ACS)....5632
      Identification Chart....5632
      Description....5633
      Identification Chart ACD Group 0....5634
      Identification Chart ACD Group 1....5635
      Identification Chart ACD Group 2....5636
      Identification Chart ACD Group 3....5637
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)....5638
      Identification Chart....5638
      Description....5639
      Identification Chart ACD Group 0....5640
      Identification Chart ACD Group 1....5641
      Identification Chart ACD Group 2....5642
      Identification Chart ACD Group 3....5643
    SERVICE PC (LAPTOP COMPUTER)....5644
      Connecting Remote Start Tool....5644
      Connecting Remote Start Tool (Service Tool)....5644
    CALIBRATION....5646
      Description....5646
      Actuator Testing....5646
      Lift And Tilt Calibration (SJC)....5649
      Hydrostatic Pump Calibration (SJC)....5651
      Lift And Tilt Calibration (ACS)....5656
    STEERING DRIFT COMPENSATION....5658
      Description....5658
      Operation....5658
    FLYWHEEL RPM SENSOR....5660
      Description....5660
      Removal....5660
      Installation....5661
    CONTROL PANEL SETUP....5662
      Right Panel Setup (Deluxe Instrumentation Panel)....5662
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....5666
      Password Description....5666
      Changing The Owner Password....5666
      Changing The User Passwords....5667
      Password Lockout Feature....5667
    PASSWORD SETUP (KEYLESS START PANEL)....5668
      Password Description....5668
      Changing The Owner Password....5668
      Password Lockout Feature....5668
    MAINTENANCE CLOCK....5670
      Description....5670
      Setup....5671
      Reset....5674
    BACK-UP ALARM SYSTEM....5676
      Description....5676
      Inspecting....5676
      Adjusting Switch Position....5677
      Troubleshooting (Standard And ACS)....5678
      Troubleshooting (Joystick)....5679
      Alarm Removal And Installation....5680
      Switch Removal And Installation....5680
    FRONT HORN....5682
      Removal And Installation....5682
      Troubleshooting....5683
      Troubleshooting (Joystick)....5684
  ENGINE SERVICE....5686
    ENGINE INFORMATION....5690
      Description....5690
      Specifications....5691
      Torque Values....5694
      Troubleshooting....5694
      Engine Removal And Installation....5696
      Engine Mount Replacement....5705
      Compression - Testing....5706
    ENGINE SPEED CONTROL (HAND)....5708
      Removal And Installation....5708
      Disassembly And Assembly....5708
      Cable Removal And Installation....5709
    ENGINE SPEED CONTROL (FOOT)....5710
      Removal And Installation....5710
      Disassembly And Assembly....5711
    MUFFLER....5714
      Removal And Installation....5714
    AIR CLEANER....5716
      Housing Removal And Installation....5716
    ENGINE COOLING SYSTEM....5718
      Radiator Removal And Installation....5718
      Hydraulic Fan Description....5720
      Fan Duct Removal And Installation....5720
      Hydraulic Fan Motor Assembly Removal And Installation....5721
      Hydraulic Fan Motor Removal And Installation....5722
      Hydraulic Fan Motor Disassembly And Assembly....5724
      Blower Housing Removal And Installation....5725
      Water Pump Removal And Installation....5726
      Water Pump Disassembly And Assembly....5726
      Thermostat Housing Removal And Installation....5727
      Thermostat - Testing....5728
    LUBRICATION SYSTEM....5730
      Oil Pan Removal And Installation....5730
      Oil Pump Removal And Installation....5730
      Relief Valve - Testing....5731
      Oil Pump Inspection....5731
      Oil Filter Cooler Removal And Installation....5732
      Engine Oil Pressure - Testing....5733
    FUEL SYSTEM....5734
      Fuel Shutoff Solenoid - Testing....5734
      Fuel Shutoff Solenoid Removal And Installation....5734
      Fuel Injection Pump - Testing....5735
      Fuel Injection Pump Assembly Removal And Installation....5736
      Governor Housing Disassembly And Assembly....5739
      Governor Disassembly And Assembly....5741
      Fuel Camshaft Removal And Installation....5743
      Fuel Injection Pump Removal And Installation....5746
      Fuel Injection Pump - Timing....5748
      Fuel Injector Removal And Installation....5750
      Fuel Injector Nozzle Pressure - Checking....5751
      Nozzle Spray Condition....5752
      Valve Seat Tightness....5752
    CYLINDER HEAD....5754
      Glow Plugs - Testing....5754
      Glow Plugs Removal And Installation....5754
      Valve Clearance Adjustment....5755
      Valve Timing - Inspecting....5756
      Cylinder Head Removal And Installation....5757
      Cylinder Head Disassembly And Assembly....5760
      Cylinder Head - Servicing....5761
      Cylinder Head Top Clearance....5762
      Valve Guide - Inspecting....5763
      Valve Guide Removal And Installation....5763
      Reconditioning The Valve And Valve Seat....5764
      Valve Spring....5766
      Valve Tappets....5767
      Rocker Arm And Shaft - Inspecting....5768
      Bridge Arm And Bridge Arm Shaft - Inspecting....5768
      Bridge Arm Shaft - Removal And Installation....5769
      Push Rod Alignment - Inspecting....5770
    CRANKSHAFT AND PISTONS....5772
      Piston And Connecting Rod Removal And Installation....5772
      Piston And Connecting Rod - Servicing....5773
      Cylinder Bore - Inspecting....5777
      Connecting Rod Alignment....5777
      Crankshaft Gear Removal And Installation....5778
      Crankshaft And Bearings Removal And Installation....5779
      Crankshaft And Bearings - Servicing....5782
    CAMSHAFT AND TIMING GEARS....5786
      Timing Gearcase Cover Removal....5786
      Timing Gearcase Cover Installation....5787
      Timing Gears Backlash - Inspection....5790
      Idler Gear And Camshaft Removal And Installation....5790
      Camshaft - Servicing....5791
      Idler Gear And Shaft - Servicing....5792
    TURBOCHARGER....5794
      Description....5794
      Testing....5794
      Removal And Installation....5795
    FLYWHEEL AND HOUSING....5796
      Flywheel Removal And Installation....5796
      Ring Gear Removal And Installation....5797
      Housing Removal And Installation....5798
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM....5800
      Description....5800
      Testing....5801
      Removal And Installation....5804
      Disassembly And Assembly....5805
  HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....5806
    AIR CONDITIONING SYSTEM FLOW....5808
      Description....5808
      Chart....5809
      Components....5810
      Safety Equipment....5813
    REGULAR MAINTENANCE....5814
      Filters....5814
      Belt Adjustment....5815
      Belt Replacement....5815
      Air Conditioning Service Chart....5816
      Evaporator / Heater Coil....5817
    TROUBLESHOOTING....5818
      Blower Motor Does Not Operate....5818
      Blower Motor Operates Normally, But Air Flow Is Insufficient....5818
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....5818
      The Compressor Does Not Operate At All, Or Operates Improperly....5818
      Gauge Pressure Related Troubleshooting....5819
      Troubleshooting Tree....5821
      Temperature / Pressure Chart....5825
      Poor A/C Performance....5827
      HVAC Repair And Leaks....5828
      Electrical System....5829
      Engine Coolant Bypassing The Heater Valve....5835
      Heater Valve Not Opening Or Closing....5836
    SYSTEM CHARGING AND RECLAMATION....5838
      Refrigerant Identification....5838
      Reclamation And Charging With Recovery / Charging Unit....5839
    COMPRESSOR....5842
      Removal And Installation....5842
      Oil....5843
      Oil Check....5844
    CONDENSER....5846
      Removal And Installation....5846
    RECEIVER / DRIER....5848
      Receiver / Drier Removal And Installation....5848
      Pressure Relief Valve Removal And Installation....5849
      Pressure Switch Removal And Installation....5850
      Schraeder Valve Removal And Installation....5851
    EVAPORATOR / HEATER UNIT....5852
      Removal And Installation....5852
    THERMOSTAT....5854
      Description....5854
      Removal And Installation....5855
    EXPANSION VALVE....5856
      Removal And Installation....5856
    EVAPORATOR COIL....5858
      Removal And Installation....5858
    HEATER COIL....5860
      Removal And Installation....5860
    BLOWER FAN....5862
      Removal And Installation....5862
      Disassembly And Assembly....5862
    HEATER VALVE....5866
      Removal And Installation....5866
  SPECIFICATIONS....5868
    (T550) LOADER SPECIFICATIONS....5870
      Machine Dimensions....5870
      Performance....5871
      Engine....5871
      Drive System....5872
      Controls....5872
      Hydraulic System....5873
      Electrical System....5874
      Capacities....5874
      Tracks....5875
      Ground Pressure....5875
    TECHINCAL SERVICE GUIDE SPECIFICATIONS....5876
      Engine....5876
      Engine Torques....5876
      Cooling System....5876
      Loader Torques....5877
      Hydraulic / Hydrostatic System....5877
      Fuel Consumption....5877
    TORQUE SPECIFICATIONS FOR BOLTS....5878
      Torque For General SAE Bolts....5878
      Torque For General Metric Bolts....5879
    HYDRAULIC CONNECTION SPECIFICATIONS....5880
      Straight Thread O-ring Fitting....5880
      Flare Fitting....5881
      Tubelines And Hoses....5881
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....5882
      Specifications....5882
    CONVERSIONS....5884
      Decimal And Millimeter Equivalent Chart....5884
      U.S. To Metric Conversion Chart....5884
    SERVICE TOOLS REQUIRED....5886
      Remote Start Tools....5886
      Hydraulic Tools....5887
      Mainframe And Drive Tools....5889
      Electrical Tools....5889
      Engine Tools....5890
      HVAC Tools....5892
  ALPHABETICAL INDEX....5894
6989683 (08-12) - T590 Compact Track Loader Service Manual....5896
  MAINTENANCE SAFETY....5898
  CONTENTS....5900
  FOREWORD....5902
    FOREWORD....5904
    SAFETY INSTRUCTIONS....5906
    FIRE PREVENTION....5908
      Maintenance....5908
      Operation....5908
      Electrical....5908
      Hydraulic System....5908
      Fueling....5908
      Starting....5908
      Spark Arrester Exhaust System....5908
      Welding And Grinding....5909
      Fire Extinguishers....5909
    SERIAL NUMBER LOCATIONS....5910
      Loader Serial Number....5910
      Engine Serial Number....5910
    DELIVERY REPORT....5911
    LOADER IDENTIFICATION....5912
  SAFETY AND MAINTENANCE....5914
    LIFTING AND BLOCKING THE LOADER....5916
      Procedure....5916
    LIFT ARM SUPPORT DEVICE....5918
      Description....5918
      Installing....5919
      Removing....5920
    OPERATOR CAB....5922
      Description....5922
      Raising....5923
      Lowering....5924
      Cab Door Sensor....5925
      Special Applications Kit....5925
      Special Applications Kit Inspection And Maintenance....5925
      Forestry Door And Window Kit....5926
      Forestry Door And Window Kit Inspection And Maintenance....5926
    TRANSPORTING THE LOADER ON A TRAILER....5928
      Loading And Unloading....5928
      Fastening....5928
    TOWING THE LOADER....5930
      Procedure....5930
    REMOTE START TOOL KIT- MEL1563....5932
      Remote Start Tool - MEL1563....5932
      Service Tool Harness Communicator - MEL1566....5934
      Remote Start Procedure....5934
    REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....5938
      Description....5938
      Remote Start Tool (Service Tool) - 7022042....5939
      Loader Service Tool Harness - 6689747....5940
      Computer Service Tool Harness - 6689746....5941
      Remote Start Procedure....5942
    SERVICE SCHEDULE....5946
      Maintenance Intervals....5946
    ENGINE AIR CLEANER....5948
      Replacing Filters....5948
    ENGINE COOLING SYSTEM....5950
      Maintenance Platform....5950
      Cleaning....5950
      Checking And Adding Coolant....5952
      Removing And Replacing Coolant....5953
    FUEL SYSTEM....5954
      Fuel Specifications....5954
      Biodiesel Blend Fuel....5954
      Filling The Fuel Tank....5955
      Fuel Filter....5956
      Removing Air From The Fuel System....5957
    ENGINE LUBRICATION SYSTEM....5958
      Checking And Adding Engine Oil....5958
      Engine Oil Chart....5958
      Removing And Replacing Oil And Filter....5959
    HYDRAULIC / HYDROSTATIC SYSTEM....5960
      Checking And Adding Fluid....5960
      Hydraulic / Hydrostatic Fluid Chart....5960
      Removing And Replacing Hydraulic Fluid....5961
      Removing And Replacing Hydraulic / Hydrostatic Filter....5963
      Removing And Replacing Hydraulic Charge Filter....5964
      Replacing Reservoir Breather Cap....5965
    BOB-TACH (HAND LEVER)....5966
      Inspection And Maintenance....5966
    BOB-TACH (POWER)....5968
      Inspection And Maintenance....5968
    LUBRICATING THE LOADER....5970
      Lubrication Locations....5970
    SPARK ARRESTER MUFFLER....5974
      Cleaning Procedure....5974
    PIVOT PINS....5976
      Inspection And Maintenance....5976
    LOADER STORAGE AND RETURN TO SERVICE....5978
      Storage....5978
      Return To Service....5978
    STOPPING THE ENGINE AND LEAVING THE LOADER....5980
      Procedure....5980
    EMERGENCY EXIT....5982
      Rear Window....5982
      External Access....5982
      Front Door....5983
    SEAT BELT....5986
      Inspection And Maintenance....5986
  HYDRAULIC SYSTEM....5988
    HYDRAULIC / HYDROSTATIC SCHEMATIC....5992
    HYDRAULIC SYSTEM INFORMATION....6000
      Glossary Of Hydraulic / Hydrostatic Symbols....6000
      Troubleshooting....6004
    CYLINDER (LIFT)....6006
      Testing....6006
      Removal And Installation....6007
      Parts Identification....6010
      Disassembly....6011
      Assembly....6013
    CYLINDER (TILT)....6018
      Testing....6018
      Removal And Installation....6019
      Base End Pivot Pin Removal And Installation....6020
      Parts Identification....6021
      Disassembly....6022
      Assembly....6024
    CYLINDER (BOB-TACH)....6028
      Testing....6028
      Removal And Installation....6029
      Parts Identification....6030
      Disassembly....6031
      Assembly....6033
    MAIN RELIEF VALVE....6036
      Description....6036
      Testing....6037
      Adjusting....6039
      Removal And Installation....6040
    HYDRAULIC CONTROL VALVE (STANDARD)....6042
      Description....6042
      Removal And Installation....6043
      Mount Bracket Removal And Installation....6046
      Identification Chart....6047
      Lift Load Check Valve Removal And Installation....6048
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....6049
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....6050
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....6050
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....6051
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....6051
      Port Relief Valve Removal And Installation....6052
      Plug Removal And Installation....6054
      Rubber Boot Removal And Installation....6055
      End Cap Block Removal And Installation....6055
      Lift Spool And Detent Removal And Installation....6056
      Tilt Spool Removal And Installation....6064
      Auxiliary Spool Removal And Installation....6066
      Auxiliary Solenoid Removal And Installation....6067
      Solenoid Removal And Installation....6068
      Lock Valve Removal And Installation....6069
      Lift Arm Bypass Orifice Removal And Installation....6071
      Main Relief Valve Removal And Installation....6071
      Check Valve Removal And Installation....6072
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....6074
      Description....6074
      Removal And Installation....6074
      Actuator Removal And Installation (In Loader)....6078
      Actuator Removal And Installation (Out Of Loader)....6080
      Identification Chart....6083
      Mount Bracket Removal And Installation....6084
      Lift Load Check Valve Removal And Installation....6084
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....6085
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....6086
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....6086
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....6087
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....6087
      Port Relief Valve Removal And Installation....6088
      Plug Removal And Installation....6090
      End Cap Block Removal And Installation....6091
      Lift Spool Removal And Installation....6091
      Lift Spool Disassembly And Assembly....6093
      Tilt Spool Removal And Installation....6094
      Auxiliary Spool Removal And Installation....6096
      Auxiliary Solenoid Removal And Installation....6097
      Solenoid Removal And Installation....6098
      Lock Valve Removal And Installation....6099
      Lift Arm Bypass Orifice Removal And Installation....6101
      Main Relief Valve Removal And Installation....6101
      Check Valve Removal And Installation....6102
    LIFT ARM BYPASS CONTROL VALVE....6104
      Description....6104
      Testing....6104
      Removal And Installation....6105
      Bracket Removal And Installation....6106
      Disassembly And Assembly....6106
    HYDRAULIC PUMP....6108
      Description....6108
      Pump Test At Quick Couplers....6109
      Direct Pump Test (Standard Section)....6111
      Direct Pump Test (Charge Section)....6113
      Removal And Installation....6115
      Hydraulic Pump Startup....6117
      Parts Identification....6118
      Disassembly And Assembly....6119
    HYDRAULIC PUMP (HIGH FLOW)....6120
      Description....6120
      Pump Test At Quick Couplers....6121
      Direct Pump Test (Standard Section)....6123
      Direct Pump Test (Charge Section)....6124
      Direct Pump Test (High Flow Section)....6126
      High Flow Relief Valve Adjustment....6128
      High Flow Relief Valve Removal And Installation....6129
      Solenoid Removal And Installation....6130
      Removal And Installation....6131
      Hydraulic Pump Startup....6133
      Parts Identification....6134
      Disassembly And Assembly....6135
    HYDRAULIC / HYDROSTATIC FILTERS....6136
      Description....6136
      Housing Removal And Installation....6136
    HYDRAULIC FLUID RESERVOIR....6138
      Description....6138
      Removal And Installation....6138
      Hydraulic Fluid Screen....6139
    OIL COOLER....6140
      Description....6140
      Removal And Installation....6140
    BUCKET POSITION VALVE....6142
      Description....6142
      Solenoid Removal And Installation....6142
      Solenoid Testing....6143
      Removal And Installation....6144
      Disassembly And Assembly....6146
    REAR AUXILIARY DIVERTER VALVE....6148
      Description....6148
      Solenoid Testing....6148
      Removal And Installation....6149
      Disassembly And Assembly....6150
    BOB-TACH (POWER) BLOCK....6156
      Description....6156
      Removal And Installation....6156
      Disassembly And Assembly....6158
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....6166
      Description....6166
      Removal And Installation....6166
      Disassembly And Assembly....6166
  HYDROSTATIC SYSTEM....6168
    HYDROSTATIC SYSTEM INFORMATION....6170
      Description....6170
      Troubleshooting....6171
    HYDROSTATIC DRIVE MOTOR....6172
      Description....6172
      Removing And Replacing Oil....6173
      Removal And Installation....6175
      Parts Identification....6177
      Disassembly....6179
      Assembly....6187
    CHARGE PRESSURE....6196
      Description....6196
      Testing....6197
      Adjusting....6198
      Sender Removal And Installation....6200
    HYDROSTATIC PUMP....6202
      Description....6202
      Removal And Installation....6203
      Hydrostatic Pump Startup....6204
      Replenishing / High Pressure Relief Valve Removal And Installation....6205
      Parts Identification (Left Half)....6206
      Parts Identification (Right Half)....6207
      Disassembly....6208
      Assembly....6215
    HYDROSTATIC PUMP (SJC)....6222
      Description....6222
      Hydraulic Controller Removal And Installation....6223
      Removal And Installation....6225
      Hydrostatic Pump Startup....6227
      Parts Identification....6228
      High Pressure Relief And Bypass Valve....6229
      Charge Relief Valve....6230
      Disassembly And Assembly....6231
      Mechanical Neutral Adjustment....6244
      Hydraulic Controller Neutral Adjustment....6247
    DRIVE BELT....6250
      Belt Adjustment....6250
      Belt Replacement....6251
    DRAIN MANIFOLD....6254
      Description....6254
      Drain Manifold Removal And Installation....6254
  DRIVE SYSTEM....6256
    BRAKE....6258
      Description....6258
      Block Removal And Installation....6259
      Block Disassembly And Assembly....6261
    TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED)....6262
      Description....6262
      Checking Tension....6263
      Adjusting Tension....6264
      Track Removal And Installation....6265
      Idler (Front) Removal And Installation....6267
      Track Tensioner Disassembly And Assembly....6270
      Idler (Rear) Removal And Installation....6272
      Roller Removal And Installation....6272
      Sprocket Removal And Installation....6273
      Track Housing Removal And Installation....6274
    TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION)....6276
      Description....6276
      Checking Tension....6277
      Adjusting Tension....6278
      Track Removal And Installation....6279
      Idler (Front) Removal And Installation....6281
      Track Tensioner Disassembly And Assembly....6284
      Idler (Rear) Removal And Installation....6286
      Leaf Spring Removal And Installation....6287
      Sprocket Removal And Installation....6288
      Track Housing Removal And Installation....6289
    TRACK MAINTENANCE....6292
      Track Damage Identification....6292
  MAINFRAME....6304
    SEAT BAR....6308
      Description....6308
      Removal And Installation....6308
      Disassembly And Assembly....6309
      Compression Spring Disassembly And Assembly....6310
    OPERATOR CAB....6312
      Gas Spring Removal And Installation....6312
      Gas Spring Bracket Disassembly And Assembly....6313
      Removal And Installation....6313
    OPERATOR SEAT (SUSPENSION)....6316
      Removal And Installation....6316
      Slide Rail Removal And Installation....6316
      Seat Belt Removal And Installation....6317
      Lower Cushion Removal....6317
      Lower Cushion Installation....6318
      Back Cushion Removal And Installation....6318
      Shock Removal And Installation....6319
      3-Point Seat Belt Removal And Installation....6319
    BOB-TACH (HAND LEVER)....6322
      Description....6322
      Removal And Installation....6322
      Lever And Wedge Disassembly And Assembly....6324
      Pivot Pin Bushing And Seal Removal And Installation....6326
    BOB-TACH (POWER)....6328
      Description....6328
      Removal And Installation....6328
      Lever And Wedge Disassembly And Assembly....6331
      Pivot Pin Bushing And Seal Removal And Installation....6332
    LIFT ARMS....6334
      Stabilizer Bar Removal And Installation....6334
      Link Removal And Installation....6335
      Removal And Installation....6336
    REAR GRILLE....6340
      Removing....6340
      Installing....6340
    REAR DOOR (TAILGATE)....6342
      Removal And Installation....6342
      Striker Removal And Installation....6343
      Striker Disassembly And Assembly....6343
      Striker Adjusting....6344
      Latch Removal And Installation....6344
    FUEL TANK....6346
      Removal And Installation....6346
      Fuel Level Sender Removal And Installation....6348
      Fuel Fill Screen Removal And Installation....6349
    CONTROL PEDALS AND LINKAGES....6350
      Description....6350
      Pedal Removal And Installation....6350
      Linkage Removal And Installation....6351
      Pedal (Adjusting)....6352
      Floor Pan Removal And Installation....6353
    CONTROL PEDALS AND LINKAGES (ACS)....6354
      Description....6354
      Pedal Removal And Installation....6354
      Linkage Removal And Installation....6355
      Pedal (Adjusting)....6355
      Floor Pan Removal And Installation....6356
    CONTROL PANEL....6358
      Description....6358
      Removal And Installation....6359
      Disassembly And Assembly....6360
      Linkage Removal And Installation....6362
      Pintle Arm Disassembly And Assembly....6366
      Linkage Neutral (Adjusting)....6367
      Linkage Travel (Adjusting)....6371
      Shock Removal And Installation....6375
    CONTROL PANEL (SJC)....6376
      Description....6376
      Removal And Installation....6376
    CONTROL HANDLE / LEVER....6378
      Description....6378
      Lever Removal And Installation....6378
      Boot Removal And Installation....6379
    CONTROL HANDLE / LEVER (ACS)....6380
      Description....6380
      Handle Sensor Removal And Installation....6380
      Handle Removal And Installation....6383
      Handle Disassembly And Assembly....6384
      Lever Removal And Installation....6384
      Boot Removal And Installation....6385
    CONTROL HANDLE / LEVER (SJC)....6386
      Description....6386
      Joystick Testing....6386
      Joystick Removal And Installation....6387
    ACCESS PANEL (INSIDE)....6388
      Removal And Installation (Left)....6388
      Removal And Installation (Right)....6388
    ACCESS PANEL (INSIDE) (SJC)....6390
      Removal And Installation (Left)....6390
      Removal And Installation (Right)....6390
    WINDOW (REAR)....6392
      Removal And Installation....6392
      Disassembly And Assembly....6392
    WINDOW (TOP)....6394
      Removal And Installation....6394
    WINDOW (SIDE)....6396
      Removal And Installation....6396
    CAB DOOR....6398
      Description....6398
      Removal And Installation....6398
      Disassembly And Assembly....6399
      Aligning....6400
      Adjusting....6401
      Checking Operation....6401
    ARMREST....6402
      Description....6402
      Removal And Installation....6403
      Disassembly And Assembly....6404
    LEFT SIDE LOWER PANEL....6406
      Removal And Installation....6406
      Disassembly And Assembly....6408
    RIGHT SIDE LOWER PANEL....6410
      Removal And Installation....6410
      Disassembly And Assembly....6411
    HEADLINER....6414
      Removal And Installation....6414
  ELECTRICAL SYSTEM AND ANALYSIS....6416
    ELECTRICAL SCHEMATICS....6422
    ELECTRICAL SYSTEM INFORMATION....6454
      Glossary Of Electrical Symbols....6454
      Standard Cab Harness Connectors....6457
      Deluxe Cab Harness Connectors....6458
      Mainframe Harness Connectors - Manual Controls....6459
      Mainframe Harness Connectors - SJC....6460
      Description....6461
      Troubleshooting....6462
      Fuse And Relay Location / Identification....6463
      Solenoid Testing....6465
    BATTERY....6466
      Removal And Installation....6466
      Servicing....6467
      Using A Booster Battery (Jump Starting)....6468
    ALTERNATOR....6470
      Belt Adjustment....6470
      Belt Replacement....6470
      Charging System Inspection....6471
      Alternator Voltage Testing....6472
      Low Voltage Testing....6472
      High Voltage Testing....6473
      Removal And Installation....6474
      Parts Identification....6476
    STARTER....6478
      Testing....6478
      Removal And Installation....6478
      Parts Identification....6479
    INSTRUMENT PANELS....6480
      Left Panel....6480
      Display Screen....6482
      Right Panel (Standard Key Panel)....6483
      Right Panel (Keyless Start Panel)....6484
      Right Panel (Deluxe Instrumentation Panel)....6485
      Left Switch Panel....6487
      Right Switch Panel....6487
      Left Side Lower Panel....6488
      Right Side Lower Panel....6488
      Left Panel Removal And Installation....6489
      Right Panel (Standard Key Panel) Removal And Installation....6489
      Right Panel (Keyless Start Panel) Removal And Installation....6490
      Right Panel (Deluxe Instrumentation Panel) Removal And Installation....6490
      Key Switch Disassembly And Assembly....6491
      Alarm Disassembly And Assembly....6491
      Left Switch Panel Removal And Installation....6492
      Right Switch Panel Removal And Installation....6492
    LIGHTS....6494
      Front Removal And Installation....6494
      Rear Removal And Installation....6495
      Cab Light Removal And Installation....6495
    BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)....6496
      Description....6496
      Connector Identification....6497
      Removal And Installation....6503
    BOBCAT CONTROLLER (ACS)....6504
      Description....6504
      Connector And Wire Identification....6505
      Removal And Installation....6506
    BOBCAT CONTROLLER (SJC) (DRIVE)....6508
      Description....6508
      Connector Identification....6509
      Removal And Installation....6511
    DIAGNOSTIC SERVICE CODES....6512
      Viewing Service Codes....6512
      Service Codes List....6513
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....6520
      Description....6520
      Inspecting The BICS (Engine STOPPED - Key ON)....6521
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....6521
      Inspecting The Seat Bar Sensor (Engine RUNNING)....6521
      Inspecting The Traction Lock (Engine RUNNING)....6521
      Inspecting The Lift Arm Bypass Control....6521
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....6521
      Troubleshooting....6522
    SEAT BAR SENSOR....6524
      Description....6524
      Troubleshooting....6524
      Testing....6525
      Removal....6526
      Installation....6528
      Bobcat Interlock Control System (BICS) Circuit Test....6529
    TRACTION LOCK....6532
      Description....6532
      Troubleshooting....6533
      Inspecting....6534
    CONTROL SYSTEM (ACS)....6536
      Description....6536
      Troubleshooting....6537
      Handle Sensor Connector Disassembly And Assembly....6538
      Switch Handle Removal....6539
      Switch Handle Installation....6541
      Actuator Connector Disassembly And Assembly....6544
      Handle Lock Solenoid Removal And Installation....6545
      Handle Lock Solenoid Disassembly And Assembly....6545
      Foot Sensor Removal And Installation....6546
      Foot Sensor Disassembly And Assembly....6547
      Foot Sensor Lock Solenoid Removal And Installation....6547
    ELECTRICAL / HYDRAULIC CONTROLS....6548
      Identification Chart....6548
      Description....6549
      Identification Chart ACD Group 0....6550
      Identification Chart ACD Group 1....6551
      Identification Chart ACD Group 2....6552
      Identification Chart ACD Group 3....6553
    ELECTRICAL / HYDRAULIC CONTROLS (ACS)....6554
      Identification Chart....6554
      Description....6555
      Identification Chart ACD Group 0....6556
      Identification Chart ACD Group 1....6557
      Identification Chart ACD Group 2....6558
      Identification Chart ACD Group 3....6559
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)....6560
      Identification Chart....6560
      Description....6561
      Identification Chart ACD Group 0....6562
      Identification Chart ACD Group 1....6563
      Identification Chart ACD Group 2....6564
      Identification Chart ACD Group 3....6565
    SERVICE PC (LAPTOP COMPUTER)....6566
      Connecting Remote Start Tool....6566
      Connecting Remote Start Tool (Service Tool)....6566
    CALIBRATION....6568
      Description....6568
      Actuator Testing....6568
      Lift And Tilt Calibration (SJC)....6571
      Hydrostatic Pump Calibration (SJC)....6573
      Lift And Tilt Calibration (ACS)....6578
    STEERING DRIFT COMPENSATION....6580
      Description....6580
      Operation....6580
    FLYWHEEL RPM SENSOR....6582
      Description....6582
      Removal....6582
      Installation....6583
    CONTROL PANEL SETUP....6584
      Right Panel Setup (Deluxe Instrumentation Panel)....6584
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....6588
      Password Description....6588
      Changing The Owner Password....6588
      Changing The User Passwords....6589
      Password Lockout Feature....6589
    PASSWORD SETUP (KEYLESS START PANEL)....6590
      Password Description....6590
      Changing The Owner Password....6590
      Password Lockout Feature....6590
    MAINTENANCE CLOCK....6592
      Description....6592
      Setup....6593
      Reset....6596
    BACK-UP ALARM SYSTEM....6598
      Description....6598
      Inspecting....6598
      Adjusting Switch Position....6599
      Troubleshooting (Standard And ACS)....6600
      Troubleshooting (Joystick)....6601
      Alarm Removal And Installation....6602
      Switch Removal And Installation....6602
    FRONT HORN....6604
      Removal And Installation....6604
      Troubleshooting....6605
      Troubleshooting (Joystick)....6606
  ENGINE SERVICE....6608
    ENGINE INFORMATION....6612
      Description....6612
      Specifications....6613
      Torque Values....6616
      Troubleshooting....6616
      Engine Removal And Installation....6618
      Engine Mount Replacement....6627
      Compression - Testing....6628
    ENGINE SPEED CONTROL (HAND)....6630
      Removal And Installation....6630
      Disassembly And Assembly....6630
      Cable Removal And Installation....6631
    ENGINE SPEED CONTROL (FOOT)....6632
      Removal And Installation....6632
      Disassembly And Assembly....6633
    MUFFLER....6636
      Removal And Installation....6636
    AIR CLEANER....6638
      Housing Removal And Installation....6638
    ENGINE COOLING SYSTEM....6640
      Radiator Removal And Installation....6640
      Hydraulic Fan Description....6642
      Fan Duct Removal And Installation....6642
      Hydraulic Fan Motor Assembly Removal And Installation....6643
      Hydraulic Fan Motor Removal And Installation....6644
      Hydraulic Fan Motor Disassembly And Assembly....6646
      Blower Housing Removal And Installation....6647
      Water Pump Removal And Installation....6648
      Water Pump Disassembly And Assembly....6648
      Thermostat Housing Removal And Installation....6649
      Thermostat - Testing....6650
    LUBRICATION SYSTEM....6652
      Oil Pan Removal And Installation....6652
      Oil Pump Removal And Installation....6652
      Relief Valve - Testing....6653
      Oil Pump Inspection....6653
      Oil Filter Cooler Removal And Installation....6654
      Engine Oil Pressure - Testing....6655
    FUEL SYSTEM....6656
      Fuel Shutoff Solenoid - Testing....6656
      Fuel Shutoff Solenoid Removal And Installation....6656
      Fuel Injection Pump - Testing....6657
      Fuel Injection Pump Assembly Removal And Installation....6658
      Governor Housing Disassembly And Assembly....6661
      Governor Disassembly And Assembly....6663
      Fuel Camshaft Removal And Installation....6665
      Fuel Injection Pump Removal And Installation....6668
      Fuel Injection Pump - Timing....6670
      Fuel Injector Removal And Installation....6672
      Fuel Injector Nozzle Pressure - Checking....6673
      Nozzle Spray Condition....6674
      Valve Seat Tightness....6674
    CYLINDER HEAD....6676
      Glow Plugs - Testing....6676
      Glow Plugs Removal And Installation....6676
      Valve Clearance Adjustment....6677
      Valve Timing - Inspecting....6678
      Cylinder Head Removal And Installation....6679
      Cylinder Head Disassembly And Assembly....6682
      Cylinder Head - Servicing....6683
      Cylinder Head Top Clearance....6684
      Valve Guide - Inspecting....6685
      Valve Guide Removal And Installation....6685
      Reconditioning The Valve And Valve Seat....6686
      Valve Spring....6688
      Valve Tappets....6689
      Rocker Arm And Shaft - Inspecting....6690
      Bridge Arm And Bridge Arm Shaft - Inspecting....6690
      Bridge Arm Shaft - Removal And Installation....6691
      Push Rod Alignment - Inspecting....6692
    CRANKSHAFT AND PISTONS....6694
      Piston And Connecting Rod Removal And Installation....6694
      Piston And Connecting Rod - Servicing....6695
      Cylinder Bore - Inspecting....6699
      Connecting Rod Alignment....6699
      Crankshaft Gear Removal And Installation....6700
      Crankshaft And Bearings Removal And Installation....6701
      Crankshaft And Bearings - Servicing....6704
    CAMSHAFT AND TIMING GEArS....6708
      Timing Gearcase Cover Removal....6708
      Timing Gearcase Cover Installation....6709
      Timing Gears Backlash - Inspection....6712
      Idler Gear And Camshaft Removal And Installation....6712
      Camshaft - Servicing....6713
      Idler Gear And Shaft - Servicing....6714
    TURBOCHARGER....6716
      Description....6716
      Testing....6716
      Removal And Installation....6717
    FLYWHEEL AND HOUSING....6718
      Flywheel Removal And Installation....6718
      Ring Gear Removal And Installation....6719
      Housing Removal And Installation....6720
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM....6722
      Description....6722
      Testing....6723
      Removal And Installation....6726
      Disassembly And Assembly....6727
  HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....6728
    AIR CONDITIONING SYSTEM FLOW....6730
      Description....6730
      Chart....6731
      Components....6732
      Safety Equipment....6735
    REGULAR MAINTENANCE....6736
      Filters....6736
      Belt Adjustment....6737
      Belt Replacement....6737
      Air Conditioning Condenser....6737
      Air Conditioning Lubrication....6737
      Air Conditioning Service Chart....6738
      Evaporator / Heater Coil....6739
    TROUBLESHOOTING....6740
      Blower Motor Does Not Operate....6740
      Blower Motor Operates Normally, But Air Flow Is Insufficient....6740
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....6740
      The Compressor Does Not Operate At All, Or Operates Improperly....6740
      Gauge Pressure Related Troubleshooting....6741
      Troubleshooting Tree....6743
      Temperature / Pressure Chart....6747
      Poor A/C Performance....6749
      HVAC Repair And Leaks....6750
      Electrical System....6751
      Engine Coolant Bypassing The Heater Valve....6757
      Heater Valve Not Opening Or Closing....6758
    SYSTEM CHARGING AND RECLAMATION....6760
      Refrigerant Identification....6760
      Reclamation And Charging With Recovery / Charging Unit....6761
    COMPRESSOR....6764
      Removal And Installation....6764
      Oil....6765
      Oil Check....6766
    CONDENSER....6768
      Removal And Installation....6768
    RECEIVER / DRIER....6770
      Receiver / Drier Removal And Installation....6770
      Pressure Relief Valve Removal And Installation....6771
      Pressure Switch Removal And Installation....6772
      Schraeder Valve Removal And Installation....6773
    EVAPORATOR / HEATER UNIT....6774
      Removal And Installation....6774
    THERMOSTAT....6776
      Description....6776
      Removal And Installation....6777
    EXPANSION VALVE....6778
      Removal And Installation....6778
    EVAPORATOR COIL....6780
      Removal And Installation....6780
    HEATER COIL....6782
      Removal And Installation....6782
    BLOWER FAN....6784
      Removal And Installation....6784
      Disassembly And Assembly....6784
    HEATER VALVE....6788
      Removal And Installation....6788
  SPECIFICATIONS....6790
    (T590) LOADER SPECIFICATIONS....6792
      Machine Dimensions....6792
      Performance....6793
      Engine....6793
      Drive System....6794
      Controls....6794
      Hydraulic System....6795
      Electrical System....6796
      Capacities....6796
      Tracks....6797
      Ground Pressure....6797
    TECHINCAL SERVICE GUIDE SPECIFICATIONS....6798
      Engine....6798
      Engine Torques....6798
      Cooling System....6798
      Loader Torques....6799
      Hydraulic / Hydrostatic System....6799
      Fuel Consumption....6799
    TORQUE SPECIFICATIONS FOR BOLTS....6800
      Torque For General SAE Bolts....6800
      Torque For General Metric Bolts....6801
    HYDRAULIC CONNECTION SPECIFICATIONS....6802
      Straight Thread O-ring Fitting....6802
      Flare Fitting....6803
      Tubelines And Hoses....6803
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....6804
      Specifications....6804
    CONVERSIONS....6806
      Decimal And Millimeter Equivalent Chart....6806
      U.S. To Metric Conversion Chart....6806
    SERVICE TOOLS REQUIRED....6808
      Remote Start Tools....6808
      Hydraulic Tools....6809
      Mainframe And Drive Tools....6811
      Electrical Tools....6811
      Engine Tools....6812
      HVAC Tools....6814
  ALPHABETICAL INDEX....6816
6990689 (10-13) - T550 Compact Track Loader Service Manual....6818
  MAINTENANCE SAFETY....6820
  CONTENTS....6822
  FOREWORD....6824
    FOREWORD....6826
    SAFETY INSTRUCTIONS....6828
    FIRE PREVENTION....6830
      Maintenance....6830
      Operation....6830
      Electrical....6830
      Hydraulic System....6830
      Fueling....6830
      Starting....6830
      Spark Arrester Exhaust System....6830
      Welding And Grinding....6831
      Fire Extinguishers....6831
    SERIAL NUMBER LOCATIONS....6832
      Loader Serial Number....6832
      Engine Serial Number....6832
    DELIVERY REPORT....6833
    LOADER IDENTIFICATION....6834
  SAFETY AND MAINTENANCE....6836
    LIFTING AND BLOCKING THE LOADER....6838
      Procedure....6838
    LIFT ARM SUPPORT DEVICE....6840
      Description....6840
      Installing....6841
      Removing....6842
    OPERATOR CAB....6844
      Description....6844
      Cab Door Sensor....6844
      Raising....6845
      Lowering....6846
      Special Applications Kit....6847
      Special Applications Kit Inspection And Maintenance....6847
      Forestry Door And Window Kit....6848
      Forestry Door And Window Kit Inspection And Maintenance....6848
    TRANSPORTING THE LOADER ON A TRAILER....6850
      Loading And Unloading....6850
      Fastening....6850
    TOWING THE LOADER....6852
      Procedure....6852
    REMOTE START TOOL KIT- MEL1563....6854
      Remote Start Tool - MEL1563....6854
      Service Tool Harness Communicator - MEL1566....6856
      Remote Start Procedure....6856
    REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....6860
      Description....6860
      Remote Start Tool (Service Tool) - 7022042....6861
      Loader Service Tool Harness - 6689747....6862
      Computer Service Tool Harness - 6689746....6863
      Remote Start Procedure....6864
    SERVICE SCHEDULE....6868
      Maintenance Intervals....6868
    ENGINE AIR CLEANER....6870
      Replacing Filters....6870
    ENGINE COOLING SYSTEM....6872
      Maintenance Platform....6872
      Cleaning....6872
      Checking And Adding Coolant....6875
      Removing and Replacing Coolant....6876
    FUEL SYSTEM....6878
      Fuel Specifications....6878
      Biodiesel Blend Fuel....6878
      Filling The Fuel Tank....6879
      Fuel Filter....6880
      Removing Air From The Fuel System....6882
    ENGINE LUBRICATION SYSTEM....6884
      Checking And Adding Engine Oil....6884
      Engine Oil Chart....6884
      Removing And Replacing Oil And Filter....6885
    HYDRAULIC / HYDROSTATIC SYSTEM....6888
      Checking And Adding Fluid....6888
      Hydraulic / Hydrostatic Fluid Chart....6888
      Removing And Replacing Hydraulic Fluid....6889
      Removing And Replacing Hydraulic / Hydrostatic Filter....6891
      Removing And Replacing Hydraulic Charge Filter....6892
      Replacing Reservoir Breather Cap....6893
    BOB-TACH (HAND LEVER)....6894
      Inspection And Maintenance....6894
    BOB-TACH (POWER)....6896
      Inspection And Maintenance....6896
    LUBRICATING THE LOADER....6898
      Lubrication Locations....6898
    PIVOT PINS....6902
      Inspection And Maintenance....6902
    LOADER STORAGE AND RETURN TO SERVICE....6904
      Storage....6904
      Return To Service....6904
    STOPPING THE ENGINE AND LEAVING THE LOADER....6906
      Procedure....6906
    EMERGENCY EXIT....6908
      Rear Window Identification....6908
      Rear Window Removal (Latches)....6908
      Rear Window Removal (Rubber Cord)....6909
      External Access (Rear Window With Latches)....6909
      External Access (Rear Window With Rubber Cord)....6910
      Front Door....6911
    SEAT BELT....6914
      Inspection And Maintenance....6914
  HYDRAULIC SYSTEM....6916
    HYDRAULIC / HYDROSTATIC SCHEMATICS....6920
    HYDRAULIC SYSTEM INFORMATION....6928
      Glossary Of Hydraulic / Hydrostatic Symbols....6928
      Troubleshooting....6932
    CYLINDER (LIFT)....6934
      Testing....6934
      Removal And Installation....6935
      Parts Identification....6938
      Disassembly....6939
      Assembly....6941
    CYLINDER (TILT)....6946
      Testing....6946
      Removal And Installation....6947
      Base End Pivot Pin Removal And Installation....6948
      Parts Identification....6949
      Disassembly....6950
      Assembly....6952
    CYLINDER (BOB-TACH)....6956
      Testing....6956
      Removal And Installation....6957
      Parts Identification....6958
      Disassembly....6959
      Assembly....6961
    MAIN RELIEF VALVE....6964
      Description....6964
      Testing....6965
      Adjusting....6967
      Removal And Installation....6968
    HYDRAULIC CONTROL VALVE (STANDARD)....6970
      Description....6970
      Removal And Installation....6971
      Mount Bracket Removal And Installation....6974
      Identification Chart....6975
      Lift Load Check Valve Removal And Installation....6976
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....6977
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....6978
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....6978
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....6979
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....6979
      Port Relief Valve Removal And Installation....6980
      Plug Removal And Installation....6982
      Rubber Boot Removal And Installation....6983
      End Cap Block Removal And Installation....6983
      Lift Spool And Detent Removal And Installation....6984
      Tilt Spool Removal And Installation....6992
      Auxiliary Spool Removal And Installation....6994
      Auxiliary Solenoid Removal And Installation....6995
      Solenoid Removal And Installation....6996
      Lock Valve Removal And Installation....6997
      Lift Arm Bypass Orifice Removal And Installation....6999
      Main Relief Valve Removal And Installation....6999
      Check Valve Removal And Installation....7000
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....7002
      Description....7002
      Removal And Installation....7002
      Actuator Removal And Installation (In Loader)....7006
      Actuator Removal And Installation (Out Of Loader)....7008
      Identification Chart....7011
      Mount Bracket Removal And Installation....7012
      Lift Load Check Valve Removal And Installation....7012
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....7013
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....7014
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....7014
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....7015
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....7015
      Port Relief Valve Removal And Installation....7016
      Plug Removal And Installation....7018
      End Cap Block Removal And Installation....7019
      Lift Spool Removal And Installation....7019
      Lift Spool Disassembly And Assembly....7021
      Tilt Spool Removal And Installation....7022
      Auxiliary Spool Removal And Installation....7024
      Auxiliary Solenoid Removal And Installation....7025
      Solenoid Removal And Installation....7026
      Lock Valve Removal And Installation....7027
      Lift Arm Bypass Orifice Removal And Installation....7029
      Main Relief Valve Removal And Installation....7029
      Check Valve Removal And Installation....7030
    LIFT ARM BYPASS CONTROL VALVE....7032
      Description....7032
      Testing....7032
      Removal And Installation....7033
      Bracket Removal And Installation....7034
      Disassembly And Assembly....7034
    HYDRAULIC PUMP....7036
      Description....7036
      Pump Test At Quick Couplers....7037
      Direct Pump Test (Standard Section)....7039
      Direct Pump Test (Charge Section)....7041
      Removal And Installation....7043
      Hydraulic Pump Startup....7045
      Parts Identification....7046
      Disassembly And Assembly....7047
    HYDRAULIC PUMP (HIGH FLOW)....7048
      Description....7048
      Pump Test At Quick Couplers....7049
      Direct Pump Test (Standard Section)....7051
      Direct Pump Test (Charge Section)....7052
      Direct Pump Test (High Flow Section)....7054
      High Flow Relief Valve Adjustment....7056
      High Flow Relief Valve Removal And Installation....7057
      Solenoid Removal And Installation....7058
      Removal And Installation....7059
      Hydraulic Pump Startup....7061
      Parts Identification....7062
      Disassembly And Assembly....7063
    HYDRAULIC / HYDROSTATIC FILTERS....7064
      Description....7064
      Housing Removal And Installation....7064
    HYDRAULIC FLUID RESERVOIR....7066
      Description....7066
      Removal And Installation....7066
      Hydraulic Fluid Screen....7067
    OIL COOLER....7068
      Removal And Installation....7068
    BUCKET POSITION VALVE....7070
      Description....7070
      Solenoid Removal And Installation....7070
      Solenoid Testing....7072
      Removal And Installation....7072
      Disassembly And Assembly....7074
    REAR AUXILIARY DIVERTER VALVE....7076
      Description....7076
      Solenoid Testing....7076
      Removal And Installation....7077
      Disassembly And Assembly....7078
    BOB-TACH (POWER) BLOCK....7084
      Description....7084
      Removal And Installation....7084
      Disassembly And Assembly....7086
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....7094
      Description....7094
      Removal And Installation....7094
      Disassembly And Assembly....7094
  HYDROSTATIC SYSTEM....7096
    HYDROSTATIC SYSTEM INFORMATION....7098
      Description....7098
      Troubleshooting....7099
    HYDROSTATIC DRIVE MOTOR....7100
      Description....7100
      Removing And Replacing Oil....7101
      Removal And Installation....7103
      Parts Identification....7105
      Disassembly....7107
      Assembly....7115
    CHARGE PRESSURE....7124
      Description....7124
      Testing....7125
      Adjusting....7126
      Sender Removal And Installation....7128
    HYDROSTATIC PUMP....7130
      Description....7130
      Removal And Installation....7131
      Hydrostatic Pump Startup....7132
      Replenishing / High Pressure Relief Valve Removal And Installation....7133
      Parts Identification (Left Half)....7134
      Parts Identification (Right Half)....7135
      Disassembly....7136
      Assembly....7143
    HYDROSTATIC PUMP (SJC)....7150
      Description....7150
      Hydraulic Controller Removal And Installation....7151
      Removal And Installation....7153
      Hydrostatic Pump Startup....7155
      Parts Identification....7156
      High Pressure Relief And Bypass Valve....7157
      Charge Relief Valve....7158
      Disassembly And Assembly....7159
      Mechanical Neutral Adjustment....7172
      Hydraulic Controller Neutral Adjustment....7175
    DRIVE BELT....7178
      Belt Adjustment....7178
      Stop Adjustment....7178
      Belt Replacement....7179
      Idler Removal And Installation....7181
    DRAIN MANIFOLD....7182
      Description....7182
      Drain Manifold Removal And Installation....7182
  DRIVE SYSTEM....7184
    BRAKE....7186
      Description....7186
      Block Removal And Installation....7186
      Block Disassembly And Assembly....7188
    TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED)....7190
      Description....7190
      Checking Tension....7191
      Adjusting Tension....7192
      Track Removal And Installation....7193
      Idler (Front) Removal And Installation....7195
      Track Tensioner Disassembly And Assembly....7198
      Idler (Rear) Removal And Installation....7200
      Roller Removal And Installation....7200
      Sprocket Removal And Installation....7201
      Track Housing Removal And Installation....7202
    TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION)....7204
      Description....7204
      Checking Tension....7205
      Adjusting Tension....7206
      Track Removal And Installation....7207
      Idler (Front) Removal And Installation....7209
      Track Tensioner Disassembly And Assembly....7212
      Idler (Rear) Removal And Installation....7214
      Leaf Spring Removal And Installation....7215
      Sprocket Removal And Installation....7216
      Track Housing Removal And Installation....7217
    TRACK MAINTENANCE....7220
      Track Damage Identification....7220
  MAINFRAME....7232
    SEAT BAR....7236
      Description....7236
      Removal And Installation....7236
      Disassembly And Assembly....7237
      Compression Spring Disassembly And Assembly....7238
    OPERATOR CAB....7240
      Gas Spring Removal And Installation....7240
      Gas Spring Bracket Disassembly And Assembly....7241
      Removal And Installation....7241
    OPERATOR SEAT (SUSPENSION)....7244
      Removal And Installation....7244
      Slide Rail Removal And Installation....7244
      Seat Belt Removal And Installation....7245
      Lower Cushion Removal....7245
      Lower Cushion Installation....7246
      Back Cushion Removal And Installation....7246
      Shock Removal And Installation....7247
      3-Point Seat Belt Removal And Installation....7247
    BOB-TACH (HAND LEVER)....7250
      Description....7250
      Removal And Installation....7250
      Lever And Wedge Disassembly And Assembly....7252
      Pivot Pin Bushing And Seal Removal And Installation....7254
    BOB-TACH (POWER)....7256
      Description....7256
      Removal And Installation....7256
      Lever And Wedge Disassembly And Assembly....7259
      Pivot Pin Bushing And Seal Removal And Installation....7260
    LIFT ARMS....7262
      Removal And Installation....7262
    REAR GRILLE....7264
      Removing....7264
      Installing....7264
      Shield Removal And Installation....7265
    REAR DOOR (TAILGATE)....7266
      Removal And Installation....7266
      Striker Removal And Installation....7267
      Striker Disassembly And Assembly....7267
      Striker (Adjusting)....7268
      Latch Removal And Installation....7268
    FUEL TANK....7270
      Removal And Installation....7270
      Fuel Level Sender Removal And Installation....7272
      Fuel Fill Screen Removal And Installation....7273
    CONTROL PEDALS AND LINKAGES....7274
      Description....7274
      Pedal Removal And Installation....7274
      Linkage Removal And Installation....7275
      Pedal (Adjusting)....7276
      Floor Pan Removal And Installation....7277
    CONTROL PEDALS AND LINKAGES (ACS)....7278
      Description....7278
      Pedal Removal And Installation....7278
      Linkage Removal And Installation....7279
      Pedal (Adjusting)....7279
      Floor Pan Removal And Installation....7280
    CONTROL PANEL....7282
      Description....7282
      Removal And Installation....7283
      Disassembly And Assembly....7284
      Linkage Removal And Installation....7286
      Pintle Arm Disassembly And Assembly....7290
      Linkage Neutral (Adjusting)....7291
      Linkage Travel (Adjusting)....7295
      Shock Removal And Installation....7299
    CONTROL PANEL (SJC)....7300
      Description....7300
      Removal And Installation....7300
    CONTROL HANDLE / LEVER....7302
      Description....7302
      Lever Removal And Installation....7302
      Boot Removal And Installation....7303
    CONTROL HANDLE / LEVER (ACS)....7304
      Description....7304
      Handle Sensor Removal And Installation....7304
      Handle Removal And Installation....7307
      Handle Disassembly And Assembly....7308
      Lever Removal And Installation....7308
      Boot Removal And Installation....7309
    CONTROL HANDLE / LEVER (SJC)....7310
      Description....7310
      Joystick Testing....7310
      Joystick Removal And Installation....7311
    ACCESS PANEL (INSIDE)....7312
      Removal And Installation (Left)....7312
      Removal And Installation (Right)....7312
    ACCESS PANEL (INSIDE) (SJC)....7314
      Removal And Installation (Left)....7314
      Removal And Installation (Right)....7314
    WINDOW (REAR)....7316
      Removal And Installation....7316
      Disassembly And Assembly....7316
    WINDOW (TOP)....7318
      Removal And Installation....7318
    WINDOW (SIDE)....7320
      Removal And Installation....7320
    CAB DOOR....7322
      Description....7322
      Removal And Installation....7322
      Disassembly And Assembly....7323
      Aligning....7324
      Adjusting....7325
      Checking Operation....7325
    ARMREST....7326
      Description....7326
      Removal And Installation....7327
      Disassembly And Assembly....7328
    LEFT SIDE LOWER PANEL....7330
      Removal And Installation....7330
      Disassembly And Assembly....7332
    RIGHT SIDE LOWER PANEL....7334
      Removal And Installation....7334
      Disassembly And Assembly....7335
    HEADLINER....7338
      Removal And Installation....7338
    FAN DUCT PANELS....7340
      Removal And Installation....7340
  ELECTRICAL SYSTEM AND ANALYSIS....7342
    ELECTRICAL SCHEMATICS....7348
    ELECTRICAL SYSTEM INFORMATION....7386
      Glossary Of Electrical Symbols....7386
      Standard Cab Harness Connectors....7389
      Deluxe Cab Harness Connectors....7390
      Mainframe Harness Connectors - Manual Controls....7391
      Mainframe Harness Connectors - SJC....7392
      Description....7393
      Troubleshooting....7394
      Fuse And Relay Location / Identification....7395
      Solenoid Testing....7397
    BATTERY....7398
      Removal And Installation....7398
      Servicing....7399
      Using A Booster Battery (Jump Starting)....7400
    ALTERNATOR BELT....7402
      Belt Adjustment....7402
      Belt Replacement....7402
      Charging System Inspection....7403
      Alternator Voltage Testing....7404
      Low Voltage Testing....7404
      High Voltage Testing....7405
      Removal And Installation....7406
      Parts Identification....7408
    STARTER....7410
      Testing....7410
      Removal And Installation....7410
      Parts Identification....7411
    INSTRUMENT PANELS....7412
      Left Panel....7412
      Display Screen....7414
      Right Panel (Standard Key Panel)....7415
      Right Panel (Keyless Start Panel)....7416
      Right Panel (Deluxe Instrumentation Panel)....7417
      Left Switch Panel....7419
      Right Switch Panel....7419
      Left Side Lower Panel....7420
      Right Side Lower Panel....7420
      Left Panel Removal And Installation....7421
      Right Panel (Standard Key Panel) Removal And Installation....7421
      Right Panel (Keyless Start Panel) Removal And Installation....7422
      Right Panel (Deluxe Instrumentation Panel) Removal And Installation....7422
      Key Switch Disassembly And Assembly....7423
      Alarm Disassembly And Assembly....7423
      Left Switch Panel Removal And Installation....7424
      Right Switch Panel Removal And Installation....7424
    LIGHTS....7426
      Front Removal And Installation....7426
      Rear Removal And Installation....7427
      Cab Light Removal And Installation....7427
    BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)....7428
      Description....7428
      Connector Identification....7429
      Removal And Installation....7435
    BOBCAT CONTROLLER (ACS)....7436
      Description....7436
      Connector And Wire Identification....7437
      Removal And Installation....7438
    BOBCAT CONTROLLER (SJC) (DRIVE)....7440
      Description....7440
      Connector Identification....7441
      Removal And Installation....7443
    ENGINE CONTROL UNIT (ECU)....7444
      Description....7444
      Cleaning....7445
      Removal And Installation....7446
    DIAGNOSTIC SERVICE CODES....7448
      Viewing Service Codes....7448
      Service Codes List....7449
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....7460
      Description....7460
      Inspecting The BICS (Engine STOPPED - Key ON)....7461
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....7461
      Inspecting The Seat Bar Sensor (Engine RUNNING)....7461
      Inspecting The Traction Lock (Engine RUNNING)....7461
      Inspecting The Lift Arm Bypass Control....7461
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....7461
      Troubleshooting....7462
    SEAT BAR SENSOR....7464
      Description....7464
      Troubleshooting....7464
      Testing....7465
      Removal....7466
      Installation....7468
      Bobcat Interlock Control System (BICS) Circuit Test....7469
    TRACTION LOCK....7472
      Description....7472
      Troubleshooting....7473
      Inspecting....7474
    CONTROL SYSTEM (ACS)....7476
      Description....7476
      Troubleshooting....7477
      Handle Sensor Connector Disassembly And Assembly....7478
      Switch Handle Removal....7479
      Switch Handle Installation....7481
      Actuator Connector Disassembly And Assembly....7484
      Handle Lock Solenoid Removal And Installation....7485
      Handle Lock Solenoid Disassembly And Assembly....7485
      Foot Sensor Removal And Installation....7486
      Foot Sensor Disassembly And Assembly....7487
      Foot Sensor Lock Solenoid Removal And Installation....7487
    ELECTRICAL / HYDRAULIC CONTROLS....7488
      Identification Chart....7488
      Description....7489
      Identification Chart ACD Group 0....7490
      Identification Chart ACD Group 1....7491
      Identification Chart ACD Group 2....7492
      Identification Chart ACD Group 3....7493
    ELECTRICAL / HYDRAULIC CONTROLS (ACS)....7494
      Identification Chart....7494
      Description....7495
      Identification Chart ACD Group 0....7496
      Identification Chart ACD Group 1....7497
      Identification Chart ACD Group 2....7498
      Identification Chart ACD Group 3....7499
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)....7500
      Identification Chart....7500
      Description....7501
      Identification Chart ACD Group 0....7502
      Identification Chart ACD Group 1....7503
      Identification Chart ACD Group 2....7504
      Identification Chart ACD Group 3....7505
    SERVICE PC (LAPTOP COMPUTER)....7506
      Connecting Remote Start Tool....7506
      Connecting Remote Start Tool (Service Tool)....7506
    CALIBRATION....7508
      Description....7508
      Actuator Testing....7508
      Lift And Tilt Calibration (SJC)....7511
      Hydrostatic Pump Calibration (SJC)....7513
      Lift And Tilt Calibration (ACS)....7518
    STEERING DRIFT COMPENSATION....7520
      Description....7520
      Operation....7520
    CONTROL PANEL SETUP....7522
      Right Panel Setup (Deluxe Instrumentation Panel)....7522
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....7526
      Password Description....7526
      Changing The Owner Password....7526
      Changing The User Passwords....7527
      Password Lockout Feature....7527
    PASSWORD SETUP (KEYLESS START PANEL)....7528
      Password Description....7528
      Changing The Owner Password....7528
      Password Lockout Feature....7528
    MAINTENANCE CLOCK....7530
      Description....7530
      Setup....7531
      Reset....7534
    BACK-UP ALARM SYSTEM....7536
      Description....7536
      Inspecting....7536
      Adjusting Switch Position....7537
      Troubleshooting (Standard And ACS)....7538
      Troubleshooting (Joystick)....7539
      Alarm Removal And Installation....7540
      Switch Removal And Installation....7540
    FRONT HORN....7542
      Removal And Installation....7542
      Troubleshooting....7543
      Troubleshooting (Joystick)....7544
    ENGINE SPEED CONTROL (HAND)....7546
      Removal And Installation....7546
    ENGINE SPEED CONTROL (FOOT)....7548
      Removal And Installation....7548
      Disassembly And Assembly....7549
  ENGINE SERVICE....7552
    ENGINE INFORMATION....7556
      Description....7556
      Specifications....7557
      Sensor Location....7559
      Torque Values....7565
      Troubleshooting....7567
      Engine Removal And Installation....7569
      Engine Mount Replacement....7579
    DIESEL OXIDATION CATALYST (DOC)....7582
      Removal And Installation....7582
    AIR CLEANER....7584
      Housing Removal And Installation....7584
    ENGINE COOLING SYSTEM....7586
      Radiator / Oil Cooler Removal And Installation....7586
      Hydraulic Fan Description....7589
      Fan Duct Removal And Installation....7589
      Hydraulic Fan Motor Assembly Removal And Installation....7590
      Hydraulic Fan Motor Removal And Installation....7591
      Hydraulic Fan Motor Disassembly And Assembly....7593
      Blower Housing Removal And Installation....7594
      Water Pump Removal And Installation....7595
      Thermostat Housing Removal And Installation....7596
      Testing The Thermostat....7597
    LUBRICATION SYSTEM....7598
      Description....7598
      Oil Pan Removal And Installation....7599
      Oil Pump Removal And Installation....7600
      Oil Pump Relief Valve Description....7601
      Oil Pump Relief Valve Removal And Installation....7601
      Oil Cooler Removal And Installation....7602
      Oil Filter Head Removal And Installation....7603
      Oil Cooler Bypass Description....7604
      Oil Cooler Bypass Removal And Installation....7604
    FUEL SYSTEM....7606
      Description....7606
      Transfer Pump / High Pressure Pump Removal And Installation....7607
      Fuel Cooler Removal And Installation....7610
      Fuel Injector Removal And Installation....7611
    CYLINDER HEAD....7614
      Glow Plugs Testing....7614
      Glow Plug Removal And Installation....7615
      Valve Clearance Adjustment....7616
      Cylinder Head Removal And Installation....7618
      Cylinder Head Disassembly And Assembly....7623
      Cylinder Head Inspection....7624
      Cylinder Head Top Clearance....7625
      Valve Step Height....7626
      Valve Stem Height....7626
      Valve Guide....7627
      Valve....7627
      Valve Spring....7628
      Rocker Arm Shaft Disassembly And Assembly....7629
      Rocker Arm Shaft Inspection....7630
      Push Rod Inspection....7630
    CRANKSHAFT AND PISTONS....7632
      Piston And Connecting Rod Removal And Installation....7632
      Piston And Connecting Rod Inspection....7633
      Crankshaft Removal And Installation....7635
      Cylinder Block Inspection....7638
      Crankshaft Inspection....7640
      Connecting Rod Inspection....7640
      Engine Component Class....7641
    CAMSHAFT....7644
      Removal And Installation....7644
      Inspecting....7645
    GEAR CASE....7648
      Gear Case Cover Removal And Installation....7648
      Gear Backlash....7649
      Gear Timing....7650
      Idle Gear Removal And Installation....7651
      Idle Gear Inspection....7651
    TURBOCHARGER....7652
      Description....7652
      Removal And Installation....7652
      Inspection....7654
    FLYWHEEL AND HOUSING....7656
      Flywheel Removal And Installation....7656
      Ring Gear Removal And Installation....7658
      Housing Removal And Installation....7658
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM....7660
      Description....7660
      Removal And Installation....7661
      Disassembly And Assembly....7665
  HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....7668
    AIR CONDITIONING SYSTEM FLOW....7670
      Description....7670
      Chart....7671
      Components....7672
      Safety Equipment....7675
    REGULAR MAINTENANCE....7676
      Filters....7676
      Belt Adjustment....7677
      Belt Replacement....7677
      Air Conditioning Condenser....7677
      Air Conditioning Lubrication....7677
      Air Conditioning Service Chart....7678
      Evaporator / Heater Coil....7679
    TROUBLESHOOTING....7682
      Blower Motor Does Not Operate....7682
      Blower Motor Operates Normally, But Air Flow Is Insufficient....7682
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....7682
      The Compressor Does Not Operate At All, Or Operates Improperly....7682
      Gauge Pressure Related Troubleshooting....7683
      Troubleshooting Tree....7685
      Temperature / Pressure Chart....7689
      Poor A/C Performance....7691
      HVAC Repair And Leaks....7692
      Electrical System....7693
      Engine Coolant Bypassing The Heater Valve....7699
      Heater Valve Not Opening Or Closing....7700
    SYSTEM CHARGING AND RECLAMATION....7702
      Refrigerant Identification....7702
      Reclamation And Charging With Recovery / Charging Unit....7703
    COMPRESSOR....7706
      Removal And Installation....7706
      Oil....7707
      Oil Check....7708
    CONDENSER....7710
      Removal And Installation....7710
    RECEIVER / DRIER....7712
      Receiver / Drier Removal And Installation....7712
      Pressure Relief Valve Removal And Installation....7713
      Pressure Switch Removal And Installation....7714
      Schraeder Valve Removal And Installation....7715
    EVAPORATOR / HEATER UNIT....7716
      Removal And Installation....7716
    THERMOSTAT....7718
      Description....7718
      Removal And Installation....7719
    EXPANSION VALVE....7720
      Removal And Installation....7720
    EVAPORATOR COIL....7722
      Removal And Installation....7722
    HEATER COIL....7724
      Removal And Installation....7724
    BLOWER FAN....7726
      Removal And Installation....7726
      Disassembly And Assembly....7726
    HEATER VALVE....7730
      Removal And Installation....7730
  SPECIFICATIONS....7732
    (T550) LOADER SPECIFICATIONS....7734
      Machine Dimensions....7734
      Performance....7735
      Engine....7735
      Drive System....7736
      Controls....7736
      Hydraulic System....7737
      Electrical System....7738
      Capacities....7738
      Tracks....7739
      Ground Pressure....7739
    TECHINCAL SERVICE GUIDE SPECIFICATIONS....7740
      Engine....7740
      Engine Torques....7740
      Cooling System....7740
      Loader Torques....7741
      Hydraulic / Hydrostatic System....7741
      Fuel Consumption....7741
    TORQUE SPECIFICATIONS FOR BOLTS....7742
      Torque For General SAE Bolts....7742
      Torque For General Metric Bolts....7743
    HYDRAULIC CONNECTION SPECIFICATIONS....7744
      Straight Thread O-ring Fitting....7744
      Flare Fitting....7745
      Tubelines And Hoses....7745
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....7746
      Specifications....7746
    CONVERSIONS....7748
      Decimal And Millimeter Equivalent Chart....7748
      U.S. To Metric Conversion Chart....7748
    SERVICE TOOLS REQUIRED....7750
      Remote Start Tools....7750
      Hydraulic Tools....7751
      Mainframe And Drive Tools....7753
      Electrical Tools....7754
      Engine Tools....7754
      HVAC Tools....7757
  ALPHABETICAL INDEX....7758
6990693 (10-13) - T590 Compact Track Loader Service Manual....7760
  MAINTENANCE SAFETY....7762
  CONTENTS....7764
  FOREWORD....7766
    FOREWORD....7768
    SAFETY INSTRUCTIONS....7770
    FIRE PREVENTION....7772
      Maintenance....7772
      Operation....7772
      Electrical....7772
      Hydraulic System....7772
      Fueling....7772
      Starting....7772
      Spark Arrester Exhaust System....7772
      Welding And Grinding....7773
      Fire Extinguishers....7773
    SERIAL NUMBER LOCATIONS....7774
      Loader Serial Number....7774
      Engine Serial Number....7774
    DELIVERY REPORT....7775
    LOADER IDENTIFICATION....7776
  SAFETY AND MAINTENANCE....7778
    LIFTING AND BLOCKING THE LOADER....7780
      Procedure....7780
    LIFT ARM SUPPORT DEVICE....7782
      Description....7782
      Installing....7783
      Removing....7784
    OPERATOR CAB....7786
      Description....7786
      Cab Door Sensor....7786
      Raising....7787
      Lowering....7788
      Special Applications Kit....7789
      Special Applications Kit Inspection And Maintenance....7789
      Forestry Door And Window Kit....7790
      Forestry Door And Window Kit Inspection And Maintenance....7790
    TRANSPORTING THE LOADER ON A TRAILER....7792
      Loading And Unloading....7792
      Fastening....7792
    TOWING THE LOADER....7794
      Procedure....7794
    REMOTE START TOOL KIT- MEL1563....7796
      Remote Start Tool - MEL1563....7796
      Service Tool Harness Communicator - MEL1566....7798
      Remote Start Procedure....7798
    REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....7802
      Description....7802
      Remote Start Tool (Service Tool) - 7022042....7803
      Loader Service Tool Harness - 6689747....7804
      Computer Service Tool Harness - 6689746....7805
      Remote Start Procedure....7806
    SERVICE SCHEDULE....7810
      Maintenance Intervals....7810
    ENGINE AIR CLEANER....7812
      Replacing Filters....7812
    ENGINE COOLING SYSTEM....7814
      Maintenance Platform....7814
      Cleaning....7814
      Checking And Adding Coolant....7817
      Removing And Replacing Coolant....7818
    FUEL SYSTEM....7820
      Fuel Specifications....7820
      Biodiesel Blend Fuel....7820
      Filling The Fuel Tank....7821
      Fuel Filter....7822
      Removing Air From The Fuel System....7824
    ENGINE LUBRICATION SYSTEM....7826
      Checking And Adding Engine Oil....7826
      Engine Oil Chart....7826
      Removing And Replacing Oil And Filter....7827
    HYDRAULIC / HYDROSTATIC SYSTEM....7830
      Checking And Adding Fluid....7830
      Hydraulic / Hydrostatic Fluid Chart....7830
      Removing And Replacing Hydraulic Fluid....7831
      Removing And Replacing Hydraulic / Hydrostatic Filter....7833
      Removing And Replacing Hydraulic Charge Filter....7834
      Replacing Reservoir Breather Cap....7835
    BOB-TACH (HAND LEVER)....7836
      Inspection And Maintenance....7836
    BOB-TACH (POWER)....7838
      Inspection And Maintenance....7838
    LUBRICATING THE LOADER....7840
      Lubrication Locations....7840
    PIVOT PINS....7844
      Inspection And Maintenance....7844
    LOADER STORAGE AND RETURN TO SERVICE....7846
      Storage....7846
      Return To Service....7846
    STOPPING THE ENGINE AND LEAVING THE LOADER....7848
      Procedure....7848
    EMERGENCY EXIT....7850
      Rear Window....7850
      Rear Window Removal (Latches)....7850
      Rear Window Removal (Rubber Cord)....7851
      External Access (Rear Window With Latches)....7852
      External Access (Rear Window With Rubber Cord)....7852
      Front Door....7853
    SEAT BELT....7856
      Inspection And Maintenance....7856
  HYDRAULIC SYSTEM....7858
    HYDRAULIC / HYDROSTATIC SCHEMATICS....7862
    HYDRAULIC SYSTEM INFORMATION....7870
      Glossary Of Hydraulic / Hydrostatic Symbols....7870
      Troubleshooting....7874
    CYLINDER (LIFT)....7876
      Testing....7876
      Removal And Installation....7877
      Parts Identification....7880
      Disassembly....7881
      Assembly....7883
    CYLINDER (TILT)....7888
      Testing....7888
      Removal And Installation....7889
      Base End Pivot Pin Removal And Installation....7890
      Parts Identification....7891
      Disassembly....7892
      Assembly....7894
    CYLINDER (BOB-TACH)....7898
      Testing....7898
      Removal And Installation....7899
      Parts Identification....7900
      Disassembly....7901
      Assembly....7903
    MAIN RELIEF VALVE....7906
      Description....7906
      Testing....7907
      Adjusting....7909
      Removal And Installation....7910
    HYDRAULIC CONTROL VALVE (STANDARD)....7912
      Description....7912
      Removal And Installation....7913
      Mount Bracket Removal And Installation....7916
      Identification Chart....7917
      Lift Load Check Valve Removal And Installation....7918
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....7919
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....7920
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....7920
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....7921
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....7921
      Port Relief Valve Removal And Installation....7922
      Plug Removal And Installation....7924
      Rubber Boot Removal And Installation....7925
      End Cap Block Removal And Installation....7925
      Lift Spool And Detent Removal And Installation....7926
      Tilt Spool Removal And Installation....7934
      Auxiliary Spool Removal And Installation....7936
      Auxiliary Solenoid Removal And Installation....7937
      Solenoid Removal And Installation....7938
      Lock Valve Removal And Installation....7939
      Lift Arm Bypass Orifice Removal And Installation....7941
      Main Relief Valve Removal And Installation....7941
      Check Valve Removal And Installation....7942
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....7944
      Description....7944
      Removal And Installation....7944
      Actuator Removal And Installation (In Loader)....7948
      Actuator Removal And Installation (Out Of Loader)....7950
      Identification Chart....7953
      Mount Bracket Removal And Installation....7954
      Lift Load Check Valve Removal And Installation....7954
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....7955
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....7956
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....7956
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....7957
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....7957
      Port Relief Valve Removal And Installation....7958
      Port Relief Valve Removal And Installation (Contd)....7959
      Plug Removal And Installation....7960
      End Cap Block Removal And Installation....7961
      Lift Spool Removal And Installation....7961
      Lift Spool Disassembly And Assembly....7963
      Tilt Spool Removal And Installation....7964
      Auxiliary Spool Removal And Installation....7966
      Auxiliary Solenoid Removal And Installation....7967
      Solenoid Removal And Installation....7968
      Lock Valve Removal And Installation....7969
      Lift Arm Bypass Orifice Removal And Installation....7971
      Main Relief Valve Removal And Installation....7971
      Check Valve Removal And Installation....7972
    LIFT ARM BYPASS CONTROL VALVE....7974
      Description....7974
      Testing....7974
      Removal And Installation....7975
      Bracket Removal And Installation....7976
      Disassembly And Assembly....7976
    HYDRAULIC PUMP....7978
      Description....7978
      Pump Test At Quick Couplers....7979
      Direct Pump Test (Standard Section)....7981
      Direct Pump Test (Charge Section)....7983
      Removal And Installation....7985
      Hydraulic Pump Startup....7987
      Parts Identification....7988
      Disassembly And Assembly....7989
    HYDRAULIC PUMP (HIGH FLOW)....7990
      Description....7990
      Pump Test At Quick Couplers....7991
      Direct Pump Test (Standard Section)....7993
      Direct Pump Test (Charge Section)....7994
      Direct Pump Test (High Flow Section)....7996
      High Flow Relief Valve Adjustment....7998
      High Flow Relief Valve Removal And Installation....7999
      Solenoid Removal And Installation....8000
      Removal And Installation....8001
      Hydraulic Pump Startup....8003
      Parts Identification....8004
      Disassembly And Assembly....8005
    HYDRAULIC / HYDROSTATIC FILTERS....8006
      Description....8006
      Housing Removal And Installation....8006
    HYDRAULIC FLUID RESERVOIR....8008
      Description....8008
      Removal And Installation....8008
      Hydraulic Fluid Screen....8009
    OIL COOLER....8010
      Description....8010
      Removal And Installation....8010
    BUCKET POSITION VALVE....8012
      Description....8012
      Solenoid Removal And Installation....8012
      Solenoid Testing....8014
      Removal And Installation....8014
      Disassembly And Assembly....8016
    REAR AUXILIARY DIVERTER VALVE....8018
      Description....8018
      Solenoid Testing....8018
      Removal And Installation....8019
      Disassembly And Assembly....8020
    BOB-TACH (POWER) BLOCK....8026
      Description....8026
      Removal And Installation....8026
      Disassembly And Assembly....8028
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....8036
      Description....8036
      Removal And Installation....8036
      Disassembly And Assembly....8036
  HYDROSTATIC SYSTEM....8038
    HYDROSTATIC SYSTEM INFORMATION....8040
      Description....8040
      Troubleshooting....8041
    HYDROSTATIC DRIVE MOTOR....8042
      Description....8042
      Removing And Replacing Oil....8043
      Removal And Installation....8045
      Parts Identification....8047
      Disassembly....8049
      Assembly....8057
    CHARGE PRESSURE....8066
      Description....8066
      Testing....8067
      Adjusting....8068
      Sender Removal And Installation....8070
    HYDROSTATIC PUMP....8072
      Description....8072
      Removal And Installation....8073
      Hydrostatic Pump Startup....8074
      Replenishing / High Pressure Relief Valve Removal And Installation....8075
      Parts Identification (Left Half)....8076
      Parts Identification (Right Half)....8077
      Disassembly....8078
      Assembly....8085
    HYDROSTATIC PUMP (SJC)....8092
      Description....8092
      Hydraulic Controller Removal And Installation....8093
      Removal And Installation....8095
      Hydrostatic Pump Startup....8097
      Parts Identification....8098
      High Pressure Relief And Bypass Valve....8099
      Charge Relief Valve....8100
      Disassembly And Assembly....8101
      Mechanical Neutral Adjustment....8114
      Hydraulic Controller Neutral Adjustment....8117
    DRIVE BELT....8120
      Belt Adjustment....8120
      Stop Adjustment....8120
      Belt Replacement....8121
      Idler Removal And Installation....8123
    DRAIN MANIFOLD....8124
      Description....8124
      Drain Manifold Removal And Installation....8124
  DRIVE SYSTEM....8126
    BRAKE....8128
      Description....8128
      Block Removal And Installation....8129
      Block Disassembly And Assembly....8131
    TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED)....8132
      Description....8132
      Checking Tension....8133
      Adjusting Tension....8134
      Track Removal And Installation....8135
      Idler (Front) Removal And Installation....8137
      Track Tensioner Disassembly And Assembly....8140
      Idler (Rear) Removal And Installation....8142
      Roller Removal And Installation....8142
      Sprocket Removal And Installation....8143
      Track Housing Removal And Installation....8144
    TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION)....8146
      Description....8146
      Checking Tension....8147
      Adjusting Tension....8148
      Track Removal And Installation....8149
      Idler (Front) Removal And Installation....8151
      Track Tensioner Disassembly And Assembly....8154
      Idler (Rear) Removal And Installation....8156
      Leaf Spring Removal And Installation....8157
      Sprocket Removal And Installation....8158
      Track Housing Removal And Installation....8159
    TRACK MAINTENANCE....8162
      Track Damage Identification....8162
  MAINFRAME....8174
    SEAT BAR....8178
      Description....8178
      Removal And Installation....8178
      Disassembly And Assembly....8179
      Compression Spring Disassembly And Assembly....8180
    OPERATOR CAB....8182
      Gas Spring Removal And Installation....8182
      Gas Spring Bracket Disassembly And Assembly....8183
      Removal And Installation....8183
    OPERATOR SEAT (SUSPENSION)....8186
      Removal And Installation....8186
      Slide Rail Removal And Installation....8186
      Seat Belt Removal And Installation....8187
      Lower Cushion Removal....8187
      Lower Cushion Installation....8188
      Back Cushion Removal And Installation....8188
      Shock Removal And Installation....8189
      3-Point Seat Belt Removal And Installation....8189
    BOB-TACH (HAND LEVER)....8192
      Description....8192
      Removal And Installation....8192
      Lever And Wedge Disassembly And Assembly....8194
      Pivot Pin Bushing And Seal Removal And Installation....8196
    BOB-TACH (POWER)....8198
      Description....8198
      Removal And Installation....8198
      Lever And Wedge Disassembly And Assembly....8201
      Pivot Pin Bushing And Seal Removal And Installation....8202
    LIFT ARMS....8204
      Stabilizer Bar Removal And Installation....8204
      Link Removal And Installation....8205
      Removal And Installation....8206
    REAR GRILLE....8210
      Removing....8210
      Installing....8210
      Shield Removal And Installation....8211
    REAR DOOR (TAILGATE)....8212
      Removal And Installation....8212
      Striker Removal And Installation....8213
      Striker Disassembly And Assembly....8213
      Striker Adjusting....8214
      Latch Removal And Installation....8214
    FUEL TANK....8216
      Removal And Installation....8216
      Fuel Level Sender Removal And Installation....8218
      Fuel Fill Screen Removal And Installation....8219
    CONTROL PEDALS AND LINKAGES....8220
      Description....8220
      Pedal Removal And Installation....8220
      Linkage Removal And Installation....8221
      Pedal (Adjusting)....8222
      Floor Pan Removal And Installation....8223
    CONTROL PEDALS AND LINKAGES (ACS)....8224
      Description....8224
      Pedal Removal And Installation....8224
      Linkage Removal And Installation....8225
      Pedal (Adjusting)....8225
      Floor Pan Removal And Installation....8226
    CONTROL PANEL....8228
      Description....8228
      Removal And Installation....8229
      Disassembly And Assembly....8230
      Linkage Removal And Installation....8232
      Pintle Arm Disassembly And Assembly....8236
      Linkage Neutral (Adjusting)....8237
      Linkage Travel (Adjusting)....8241
      Shock Removal And Installation....8245
    CONTROL PANEL (SJC)....8246
      Description....8246
      Removal And Installation....8246
    CONTROL HANDLE / LEVER....8248
      Description....8248
      Lever Removal And Installation....8248
      Boot Removal And Installation....8249
    CONTROL HANDLE / LEVER (ACS)....8250
      Description....8250
      Handle Sensor Removal And Installation....8250
      Handle Removal And Installation....8253
      Handle Disassembly And Assembly....8254
      Lever Removal And Installation....8254
      Boot Removal And Installation....8255
    CONTROL HANDLE / LEVER (SJC)....8256
      Description....8256
      Joystick Testing....8256
      Joystick Removal And Installation....8257
    ACCESS PANEL (INSIDE)....8258
      Removal And Installation (Left)....8258
      Removal And Installation (Right)....8258
    ACCESS PANEL (INSIDE) (SJC)....8260
      Removal And Installation (Left)....8260
      Removal And Installation (Right)....8260
    WINDOW (REAR)....8262
      Removal And Installation....8262
      Disassembly And Assembly....8262
    WINDOW (TOP)....8264
      Removal And Installation....8264
    WINDOW (SIDE)....8266
      Removal And Installation....8266
    CAB DOOR....8268
      Description....8268
      Removal And Installation....8268
      Disassembly And Assembly....8269
      Aligning....8270
      Adjusting....8271
      Checking Operation....8271
    ARMREST....8272
      Description....8272
      Removal And Installation....8273
      Disassembly And Assembly....8274
    LEFT SIDE LOWER PANEL....8276
      Removal And Installation....8276
      Disassembly And Assembly....8278
    RIGHT SIDE LOWER PANEL....8280
      Removal And Installation....8280
      Disassembly And Assembly....8281
    HEADLINER....8284
      Removal And Installation....8284
    FAN DUCT PANELS....8286
      Removal And Installation....8286
  ELECTRICAL SYSTEM AND ANALYSIS....8288
    ELECTRICAL SCHEMATICS....8294
    ELECTRICAL SYSTEM INFORMATION....8332
      Glossary Of Electrical Symbols....8332
      Standard Cab Harness Connectors....8335
      Deluxe Cab Harness Connectors....8336
      Mainframe Harness Connectors - Manual Controls....8337
      Mainframe Harness Connectors - SJC....8338
      Description....8339
      Troubleshooting....8340
      Fuse And Relay Location / Identification....8341
      Solenoid Testing....8343
    BATTERY....8344
      Removal And Installation....8344
      Servicing....8345
      Using A Booster Battery (Jump Starting)....8346
    ALTERNATOR....8348
      Belt Adjustment....8348
      Belt Replacement....8349
      Charging System Inspection....8350
      Alternator Voltage Testing....8351
      Low Voltage Testing....8351
      High Voltage Testing....8352
      Removal And Installation....8353
      Parts Identification....8355
    STARTER....8356
      Testing....8356
      Removal And Installation....8356
      Parts Identification....8357
    INSTRUMENT PANELS....8358
      Left Panel....8358
      Display Screen....8360
      Right Panel (Standard Key Panel)....8361
      Right Panel (Keyless Start Panel)....8362
      Right Panel (Deluxe Instrumentation Panel)....8363
      Left Switch Panel....8365
      Right Switch Panel....8365
      Left Side Lower Panel....8366
      Right Side Lower Panel....8366
      Left Panel Removal And Installation....8367
      Right Panel (Standard Key Panel) Removal And Installation....8367
      Right Panel (Keyless Start Panel) Removal And Installation....8368
      Right Panel (Deluxe Instrumentation Panel) Removal And Installation....8368
      Key Switch Disassembly And Assembly....8369
      Alarm Disassembly And Assembly....8369
      Left Switch Panel Removal And Installation....8370
      Right Switch Panel Removal And Installation....8370
    LIGHTS....8372
      Front Removal And Installation....8372
      Rear Removal And Installation....8373
      Cab Light Removal And Installation....8373
    BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)....8374
      Description....8374
      Connector Identification....8375
      Removal And Installation....8381
    BOBCAT CONTROLLER (ACS)....8382
      Description....8382
      Connector And Wire Identification....8383
      Removal And Installation....8384
    BOBCAT CONTROLLER (SJC) (DRIVE)....8386
      Description....8386
      Connector Identification....8387
      Removal And Installation....8389
    ENGINE CONTROL UNIT (ECU)....8390
      Description....8390
      Cleaning....8391
      Removal And Installation....8392
    DIAGNOSTIC SERVICE CODES....8394
      Viewing Service Codes....8394
      Service Codes List....8395
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....8404
      Description....8404
      Inspecting The BICS (Engine STOPPED - Key ON)....8405
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....8405
      Inspecting The Seat Bar Sensor (Engine RUNNING)....8405
      Inspecting The Traction Lock (Engine RUNNING)....8405
      Inspecting The Lift Arm Bypass Control....8405
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....8405
      Troubleshooting....8406
    SEAT BAR SENSOR....8408
      Description....8408
      Troubleshooting....8408
      Testing....8409
      Removal....8410
      Installation....8412
      Bobcat Interlock Control System (BICS) Circuit Test....8413
    TRACTION LOCK....8416
      Description....8416
      Troubleshooting....8417
      Inspecting....8418
    CONTROL SYSTEM (ACS)....8420
      Description....8420
      Troubleshooting....8421
      Handle Sensor Connector Disassembly And Assembly....8422
      Switch Handle Removal....8423
      Switch Handle Installation....8425
      Actuator Connector Disassembly And Assembly....8428
      Handle Lock Solenoid Removal And Installation....8429
      Handle Lock Solenoid Disassembly And Assembly....8429
      Foot Sensor Removal And Installation....8430
      Foot Sensor Disassembly And Assembly....8431
      Foot Sensor Lock Solenoid Removal And Installation....8431
    ELECTRICAL / HYDRAULIC CONTROLS....8432
      Identification Chart....8432
      Description....8433
      Identification Chart ACD Group 0....8434
      Identification Chart ACD Group 1....8435
      Identification Chart ACD Group 2....8436
      Identification Chart ACD Group 3....8437
    ELECTRICAL / HYDRAULIC CONTROLS (ACS)....8438
      Identification Chart....8438
      Description....8439
      Identification Chart ACD Group 0....8440
      Identification Chart ACD Group 1....8441
      Identification Chart ACD Group 2....8442
      Identification Chart ACD Group 3....8443
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)....8444
      Identification Chart....8444
      Description....8445
      Identification Chart ACD Group 0....8446
      Identification Chart ACD Group 1....8447
      Identification Chart ACD Group 2....8448
      Identification Chart ACD Group 3....8449
    SERVICE PC (LAPTOP COMPUTER)....8450
      Connecting Remote Start Tool....8450
      Connecting Remote Start Tool (Service Tool)....8450
    CALIBRATION....8452
      Description....8452
      Actuator Testing....8452
      Lift And Tilt Calibration (SJC)....8455
      Hydrostatic Pump Calibration (SJC)....8457
      Lift And Tilt Calibration (ACS)....8462
    STEERING DRIFT COMPENSATION....8464
      Description....8464
      Operation....8464
    CONTROL PANEL SETUP....8466
      Right Panel Setup (Deluxe Instrumentation Panel)....8466
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....8470
      Password Description....8470
      Changing The Owner Password....8470
      Changing The User Passwords....8471
      Password Lockout Feature....8471
    PASSWORD SETUP (KEYLESS START PANEL)....8472
      Password Description....8472
      Changing The Owner Password....8472
      Password Lockout Feature....8472
    MAINTENANCE CLOCK....8474
      Description....8474
      Setup....8475
      Reset....8478
    BACK-UP ALARM SYSTEM....8480
      Description....8480
      Inspecting....8480
      Adjusting Switch Position....8481
      Troubleshooting (Standard And ACS)....8482
      Troubleshooting (Joystick)....8483
      Alarm Removal And Installation....8484
      Switch Removal And Installation....8484
    FRONT HORN....8486
      Removal And Installation....8486
      Troubleshooting....8487
      Troubleshooting (Joystick)....8488
    ENGINE SPEED CONTROL (HAND)....8490
      Removal And Installation....8490
    ENGINE SPEED CONTROL (FOOT)....8492
      Removal And Installation....8492
      Disassembly And Assembly....8493
  ENGINE SERVICE....8496
    ENGINE INFORMATION....8500
      Description....8500
      Specifications....8501
      Sensor Location....8503
      Torque Values....8509
      Troubleshooting....8511
      Engine Removal And Installation....8513
      Engine Mount Replacement....8523
    DIESEL OXIDATION CATALYST (DOC)....8526
      Removal And Installation....8526
    AIR CLEANER....8528
      Housing Removal And Installation....8528
    ENGINE COOLING SYSTEM....8530
      Radiator / Oil Cooler Removal And Installation....8530
      Hydraulic Fan Description....8533
      Fan Duct Removal And Installation....8533
      Hydraulic Fan Motor Assembly Removal And Installation....8534
      Hydraulic Fan Motor Removal And Installation....8535
      Hydraulic Fan Motor Disassembly And Assembly....8537
      Blower Housing Removal And Installation....8538
      Water Pump Removal And Installation....8539
      Thermostat Housing Removal And Installation....8540
      Testing The Thermostat....8541
    LUBRICATION SYSTEM....8542
      Description....8542
      Oil Pan Removal And Installation....8543
      Oil Pump Removal And Installation....8544
      Oil Pump Relief Valve Description....8545
      Oil Pump Relief Valve Removal And Installation....8545
      Oil Cooler Removal And Installation....8546
      Oil Filter Head Removal And Installation....8547
      Oil Cooler Bypass Description....8548
      Oil Cooler Bypass Removal And Installation....8548
    FUEL SYSTEM....8550
      Description....8550
      Transfer Pump / High Pressure Pump Removal And Installation....8551
      Fuel Cooler Removal And Installation....8554
      Fuel Injector Removal And Installation....8555
    CYLINDER HEAD....8558
      Glow Plugs Testing....8558
      Glow Plug Removal And Installation....8559
      Valve Clearance Adjustment....8560
      Cylinder Head Removal And Installation....8562
      Cylinder Head Disassembly And Assembly....8567
      Cylinder Head Inspection....8568
      Cylinder Head Top Clearance....8569
      Valve Step Height....8570
      Valve Stem Height....8570
      Valve Guide....8571
      Valve....8571
      Valve Spring....8572
      Rocker Arm Shaft Disassembly And Assembly....8573
      Rocker Arm Shaft Inspection....8574
      Push Rod Inspection....8574
    CRANKSHAFT AND PISTONS....8576
      Piston And Connecting Rod Removal And Installation....8576
      Piston And Connecting Rod Inspection....8577
      Crankshaft Removal And Installation....8579
      Cylinder Block Inspection....8582
      Crankshaft Inspection....8584
      Connecting Rod Inspection....8584
      Engine Component Class....8585
    CAMSHAFT....8588
      Removal And Installation....8588
      Inspecting....8589
    GEAR CASE....8592
      Gear Case Cover Removal And Installation....8592
      Gear Backlash....8593
      Gear Timing....8594
      Idle Gear Removal And Installation....8595
      Idle Gear Inspection....8595
    TURBOCHARGER....8596
      Description....8596
      Removal And Installation....8596
      Inspection....8598
    FLYWHEEL AND HOUSING....8600
      Flywheel Removal And Installation....8600
      Ring Gear Removal And Installation....8601
      Housing Removal And Installation....8601
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM....8602
      Description....8602
      Removal And Installation....8603
      Disassembly And Assembly....8607
  HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....8610
    AIR CONDITIONING SYSTEM FLOW....8612
      Description....8612
      Chart....8613
      Components....8614
      Safety Equipment....8617
    REGULAR MAINTENANCE....8618
      Filters....8618
      Belt Adjustment....8619
      Belt Replacement....8619
      Air Conditioning Condenser....8619
      Air Conditioning Lubrication....8619
      Air Conditioning Service Chart....8620
      Evaporator / Heater Coil....8621
    TROUBLESHOOTING....8624
      Blower Motor Does Not Operate....8624
      Blower Motor Operates Normally, But Air Flow Is Insufficient....8624
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....8624
      The Compressor Does Not Operate At All, Or Operates Improperly....8624
      Gauge Pressure Related Troubleshooting....8625
      Troubleshooting Tree....8627
      Temperature / Pressure Chart....8631
      Poor A/C Performance....8633
      HVAC Repair And Leaks....8634
      Electrical System....8635
      Engine Coolant Bypassing The Heater Valve....8641
      Heater Valve Not Opening Or Closing....8642
    SYSTEM CHARGING AND RECLAMATION....8644
      Refrigerant Identification....8644
      Reclamation And Charging With Recovery / Charging Unit....8645
    COMPRESSOR....8648
      Removal And Installation....8648
      Oil....8649
      Oil Check....8650
    CONDENSER....8652
      Removal And Installation....8652
    RECEIVER / DRIER....8654
      Receiver / Drier Removal And Installation....8654
      Pressure Relief Valve Removal And Installation....8655
      Pressure Switch Removal And Installation....8656
      Schraeder Valve Removal And Installation....8657
    EVAPORATOR / HEATER UNIT....8658
      Removal And Installation....8658
    THERMOSTAT....8660
      Description....8660
      Removal And Installation....8661
    EXPANSION VALVE....8662
      Removal And Installation....8662
    EVAPORATOR COIL....8664
      Removal And Installation....8664
    HEATER COIL....8666
      Removal And Installation....8666
    BLOWER FAN....8668
      Removal And Installation....8668
      Disassembly And Assembly....8668
    HEATER VALVE....8672
      Removal And Installation....8672
  SPECIFICATIONS....8674
    (T590) LOADER SPECIFICATIONS....8676
      Machine Dimensions....8676
      Performance....8677
      Engine....8677
      Drive System....8678
      Controls....8678
      Hydraulic System....8679
      Electrical System....8680
      Capacities....8680
      Tracks....8681
      Ground Pressure....8681
    TECHINCAL SERVICE GUIDE SPECIFICATIONS....8682
      Engine....8682
      Engine Torques....8682
      Cooling System....8682
      Loader Torques....8683
      Hydraulic / Hydrostatic System....8683
      Fuel Consumption....8683
    TORQUE SPECIFICATIONS FOR BOLTS....8684
      Torque For General SAE Bolts....8684
      Torque For General Metric Bolts....8685
    HYDRAULIC CONNECTION SPECIFICATIONS....8686
      Straight Thread O-ring Fitting....8686
      Flare Fitting....8687
      Tubelines And Hoses....8687
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....8688
      Specifications....8688
    CONVERSIONS....8690
      Decimal And Millimeter Equivalent Chart....8690
      U.S. To Metric Conversion Chart....8690
    SERVICE TOOLS REQUIRED....8692
      Remote Start Tools....8692
      Hydraulic Tools....8693
      Mainframe And Drive Tools....8695
      Electrical Tools....8696
      Engine Tools....8696
      HVAC Tools....8699
  ALPHABETICAL INDEX....8700
6990751 (02-14) - T630 Compact Track Loader Service Manual....8702
  MAINTENANCE SAFETY....8704
  CONTENTS....8706
  FOREWORD....8708
    FOREWORD....8710
    SAFETY INSTRUCTIONS....8712
    FIRE PREVENTION....8715
      Maintenance....8715
      Operation....8715
      Electrical....8715
      Hydraulic System....8715
      Fueling....8715
      Starting....8715
      Spark Arrester Exhaust System....8715
      Welding And Grinding....8716
      Fire Extinguishers....8716
    SERIAL NUMBER LOCATIONS....8717
      Loader Serial Number....8717
      Engine Serial Number....8717
    DELIVERY REPORT....8718
    LOADER IDENTIFICATION....8719
  SAFETY & MAINTENANCE....8721
    LIFTING AND BLOCKING THE LOADER....8723
      Procedure....8723
    LIFT ARM SUPPORT DEVICE....8725
      Description....8725
      Installing....8726
      Removing....8727
    OPERATOR CAB....8729
      Description....8729
      Raising....8730
      Lowering....8731
      Cab Door Sensor....8732
      Special Applications Kit....8733
      Special Applications Kit Inspection And Maintenance....8733
      Forestry Door And Window Kit....8734
      Forestry Door And Window Kit Inspection And Maintenance....8734
    TRANSPORTING THE LOADER ON A TRAILER....8735
      Loading And Unloading....8735
      Fastening....8735
    TOWING THE LOADER....8737
      Procedure....8737
    REMOTE START TOOL KIT-MEL1563....8739
      Remote Start Tool - MEL1563....8739
      Service Tool Harness Communicator - MEL1566....8741
      Remote Start Procedure....8741
    REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....8745
      Description....8745
      Remote Start Tool (Service Tool) - 7022042....8746
      Loader Service Tool Harness - 6689747....8747
      Computer Service Tool Harness - 6689746....8748
      Remote Start Procedure....8749
    SERVICE SCHEDULE....8753
      Maintenance Intervals....8753
    AIR CLEANER SERVICE....8755
      Replacing Filter Elements....8755
    ENGINE COOLING SYSTEM....8757
      Maintenance Platform....8757
      Cleaning....8757
      Checking And Adding Coolant....8760
      Removing And Replacing Coolant....8761
    FUEL SYSTEM....8763
      Fuel Specifications....8763
      Biodiesel Blend Fuel....8763
      Filling The Fuel Tank....8764
      Fuel Filter....8765
      Removing Air From The Fuel System....8766
    ENGINE LUBRICATION SYSTEM....8767
      Checking And Adding Engine Oil....8767
      Engine Oil Chart....8767
      Removing And Replacing Oil And Filter....8768
    HYDRAULIC / HYDROSTATIC SYSTEM....8771
      Checking And Adding Fluid....8771
      Hydraulic / Hydrostatic Fluid Chart....8771
      Removing And Replacing Hydraulic Fluid....8772
      Removing And Replacing Hydraulic / Hydrostatic Filter....8774
      Removing And Replacing Hydraulic Charge Filter....8775
      Replacing Reservoir Breather Cap....8776
    BOB-TACH (HAND LEVER)....8777
      Inspection And Maintenance....8777
    BOB-TACH (POWER)....8779
      Inspection And Maintenance....8779
    LUBRICATING THE LOADER....8781
      Lubrication Locations....8781
      Track Roller and Idler Lubrication....8783
    PIVOT PINS....8785
      Inspection And Maintenance....8785
    LOADER STORAGE AND RETURN TO SERVICE....8787
      Storage....8787
      Return To Service....8787
    STOPPING THE ENGINE AND LEAVING THE LOADER....8789
      Procedure....8789
    EMERGENCY EXIT....8791
      Rear Window Identification....8791
      Rear Window Removal (Latches)....8791
      Rear Window Removal (Rubber Cord)....8791
      External Access (Rear Window With Latches)....8792
      External Access (Rear Window With Rubber Cord)....8792
      Front Door....8792
    SEAT BELT....8795
      Inspection And Maintenance....8795
  HYDRAULIC SYSTEM....8797
    HYDRAULIC/HYDROSTATIC SCHEMATICS....8801
    HYDRAULIC SYSTEM INFORMATION....8809
      Glossary Of Hydraulic / Hydrostatic Symbols....8809
      Troubleshooting....8813
    CYLINDER (LIFT)....8815
      Testing....8815
      Removal And Installation....8816
      Parts Identification....8818
      Disassembly....8819
      Assembly....8821
    CYLINDER (TILT)....8825
      Testing....8825
      Removal And Installation....8826
      Base End Pivot Pin Removal And Installation....8828
      Disassembly....8829
      Assembly....8831
    CYLINDER (BOB-TACH)....8835
      Testing....8835
      Removal And Installation....8836
      Parts Identification....8837
      Disassembly....8838
      Assembly....8839
    MAIN RELIEF VALVE....8843
      Description....8843
      Testing....8844
      Main Relief Valve Adjustment....8846
      Main Relief Valve Removal And Installation....8846
      Auxiliary Relief Valve Adjustment....8847
      Auxiliary Relief Valve Removal And Installation....8848
    HYDRAULIC CONTROL VALVE (STANDARD)....8849
      Description....8849
      Removal And Installation....8850
      Mount Bracket Removal And Installation....8854
      Identification Chart....8855
      Lift Load Check Valve Removal And Installation....8856
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....8857
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....8858
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....8858
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....8859
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....8859
      Port Relief Valve Removal And Installation....8860
      Plug Removal And Installation....8862
      Rubber Boot Removal And Installation....8863
      End Cap Block Removal And Installation....8863
      Lift Spool And Detent Removal And Installation....8864
      Tilt Spool Removal And Installation....8872
      Auxiliary Spool Removal And Installation....8874
      Auxiliary Solenoid Removal And Installation....8875
      Solenoid Removal And Installation....8876
      Lock Valve Removal And Installation....8877
      Lift Arm Bypass Orifice Removal And Installation....8879
      Main Relief Valve Removal And Installation....8879
      Auxiliary Relief Valve Removal And Installation....8880
      Check Valve Removal And Installation....8880
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....8883
      Description....8883
      Removal And Installation....8883
      Actuator Removal And Installation (In Loader)....8888
      Actuator Removal And Installation (Out Of Loader)....8889
      Identification Chart....8892
      Mount Bracket Removal And Installation....8893
      Lift Load Check Valve Removal And Installation....8893
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....8894
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....8895
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....8895
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....8896
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....8896
      Port Relief Valve Removal And Installation....8897
      Plug Removal And Installation....8899
      End Cap Block Removal And Installation....8900
      Lift Spool Removal And Installation....8900
      Lift Spool Disassembly And Assembly....8902
      Tilt Spool Removal And Installation....8903
      Tilt Spool Disassembly And Assembly....8904
      Auxiliary Spool Removal And Installation....8905
      Auxiliary Solenoid Removal And Installation....8906
      Solenoid Removal And Installation....8907
      Lock Valve Removal And Installation....8908
      Lift Arm Bypass Orifice Removal And Installation....8910
      Main Relief Valve Removal And Installation....8910
      Auxiliary Relief Valve Removal And Installation....8911
      Check Valve Removal And Installation....8911
    LIFT ARM BYPASS CONTROL VALVE....8913
      Description....8913
      Removal And Installation....8914
      Bracket Removal And Installation....8915
      Disassembly And Assembly....8915
    HYDRAULIC PUMP....8917
      Description....8917
      Pump Test At Quick Couplers....8917
      Direct Pump Test (Standard Section)....8918
      Direct Pump Test (Charge Section)....8920
      Removal And Installation....8922
      Hydraulic Pump Startup....8924
      Parts Identification....8925
      Disassembly And Assembly....8926
    HYDRAULIC PUMP (HIGH FLOW)....8927
      Description....8927
      Pump Test At Quick Couplers....8927
      Direct Pump Test (Standard Section)....8928
      Direct Pump Test (Charge Section)....8929
      Direct Pump Test (High Flow Section)....8931
      High Flow Relief Valve Adjustment....8933
      High Flow Relief Valve Removal And Installation....8934
      Solenoid Removal And Installation....8935
      Removal And Installation....8936
      Hydraulic Pump Startup....8938
      Parts Identification....8939
      Disassembly And Assembly....8940
    HYDRAULIC / HYDROSTATIC FILTERS....8941
      Description....8941
      Housing Removal And Installation....8941
    HYDRAULIC FLUID RESERVOIR....8943
      Description....8943
      Removal And Installation....8943
      Hydraulic Fluid Screen....8944
    OIL COOLER....8945
      Description....8945
      Removal And Installation....8945
    BUCKET POSITION VALVE....8947
      Description....8947
      Solenoid Removal And Installation....8947
      Solenoid Testing....8948
      Removal And Installation....8948
      Disassembly And Assembly....8951
    REAR AUXILIARY DIVERTER VALVE....8953
      Description....8953
      Solenoid Testing....8953
      Removal And Installation....8954
      Disassembly And Assembly....8955
    BOB-TACH (POWER) BLOCK....8961
      Description....8961
      Removal And Installation....8961
      Disassembly And Assembly....8963
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....8973
      Description....8973
      Removal And Installation....8973
      Disassembly And Assembly....8973
  HYDROSTATIC SYSTEM....8975
    HYDROSTATIC SYSTEM INFORMATION....8977
      Description....8977
      Troubleshooting....8978
    HYDROSTATIC DRIVE MOTOR....8979
      Description....8979
      Removing And Replacing Fluid....8979
      Removal And Installation....8980
      Parts Identification....8982
      Disassembly And Assembly....8984
    HYDROSTATIC DRIVE MOTOR (TWO-SPEED)....8997
      Description....8997
      Removing And Replacing Fluid....8997
      Removal And Installation....8998
      Parts Identification....9000
      Disassembly And Assembly....9002
    CHARGE PRESSURE....9015
      Description....9015
      Testing....9015
      Sender Removal And Installation....9017
      Adjusting....9018
    HYDROSTATIC PUMP....9021
      Description....9021
      Removal And Installation....9022
      Hydrostatic Pump Startup....9023
      Replenishing / High Pressure Relief Valve Removal And Installation....9023
      Parts Identification (Left Half)....9024
      Parts Identification (Right Half)....9025
      Disassembly....9026
      Assembly....9033
    HYDROSTATIC PUMP (SJC)....9039
      Description....9039
      Hydraulic Controller Removal And Installation....9040
      Removal And Installation....9042
      Hydrostatic Pump Start Up....9043
      Parts Identification....9044
      High Pressure Relief And Bypass Valve....9045
      Charge Relief Valve....9046
      Disassembly And Assembly....9047
      Mechanical Neutral Adjustment....9060
      Hydraulic Controller Neutral Adjustment....9063
    DRIVE BELT....9067
      Belt Adjustment....9067
      Stop Adjustment....9067
      Belt Replacement....9068
      Tensioner Pulley Removal And Installation....9070
      Tensioner Pulley Disassembly And Assembly....9070
    TWO-SPEED / BRAKE VALVE....9071
      Description....9071
      Valve Block Removal And Installation....9072
      Valve Block Disassembly And Assembly....9074
    DRAIN MANIFOLD....9077
      Description....9077
      Drain Manifold Removal And Installation....9077
  DRIVE SYSTEM....9079
    BRAKE....9081
      Description....9081
      Block Removal And Installation....9081
      Block Disassembly And Assembly....9082
    BRAKE (TWO-SPEED)....9085
      Description....9085
    TRACK UNDERCARRIAGE COMPONENTS (SOLID- MOUNTED)....9087
      Description....9087
      Checking Tension....9088
      Adjusting Tension....9089
      Track Removal And Installation....9090
      Idler (Front) Removal And Installation....9092
      Track Tensioner Disassembly And Assembly....9095
      Idler (Rear) Removal And Installation....9097
      Roller Removal And Installation....9097
      Sprocket Removal And Installation (Single Speed)....9098
      Sprocket Removal And Installation (Two Speed)....9098
      Track Housing Removal And Installation....9099
    TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION)....9101
      Description....9101
      Checking Tension....9102
      Adjusting Tension....9103
      Track Removal And Installation....9104
      Idler (Front) Removal And Installation....9106
      Track Tensioner Disassembly And Assembly....9109
      Idler (Rear) Removal And Installation....9111
      Roller Removal And Installation....9111
      Leaf Spring Removal And Installation....9112
      Sprocket Removal And Installation (Single Speed)....9113
      Sprocket Removal And Installation (Two Speed)....9113
      Track Housing Removal And Installation....9114
    TRACK MAINTENANCE....9115
      Track Damage Identification....9115
  MAINFRAME....9127
    SEAT BAR....9131
      Description....9131
      Removal And Installation....9131
      Disassembly And Assembly....9132
      Compression Spring Disassembly And Assembly....9133
    OPERATOR CAB....9135
      Gas Spring Removal And Installation....9135
      Gas Spring Bracket Disassembly And Assembly....9136
      Removal And Installation....9136
    OPERATOR SEAT....9139
      Removal And Installation....9139
      Seat Belt Removal And Installation (Retractable)....9139
      Seat Belt And Bracket Removal And Installation (Standard)....9140
      Seat Belt Bracket Removal And Installation....9140
    OPERATOR SEAT (SUSPENSION)....9141
      Removal And Installation....9141
      Slide Rail Removal And Installation....9141
      Seat Belt Removal And Installation....9142
      Lower Cushion Removal....9142
      Lower Cushion Installation....9143
      Back Cushion Removal And Installation....9143
      Shock Removal And Installation....9144
      3-Point Seat Belt Removal And Installation....9144
    BOB-TACH (HAND LEVER)....9147
      Description....9147
      Removal And Installation....9147
      Lever And Wedge Disassembly And Assembly....9149
      Pivot Pin Bushing And Seal Removal And Installation....9151
    BOB-TACH (POWER)....9153
      Description....9153
      Removal And Installation....9153
      Lever And Wedge Disassembly And Assembly....9156
      Pivot Pin Bushing And Seal Removal And Installation....9157
    LIFT ARMS....9159
      Removal And Installation....9159
    REAR GRILLE....9161
      Removing....9161
      Installing....9162
      Shield Removal And Installation....9163
    REAR DOOR (TAILGATE)....9165
      Removal And Installation....9165
      Striker Removal And Installation....9166
      Striker Disassembly And Assembly....9166
      Striker (Adjusting)....9166
      Latch Removal And Installation....9167
    FUEL TANK....9169
      Removal And Installation....9169
      Fuel Level Sender Removal And Installation....9171
      Fuel Fill Screen Removal And Installation....9171
    CONTROL PEDALS AND LINKAGES....9173
      Description....9173
      Pedal Removal And Installation....9173
      Linkage Removal And Installation....9174
      Pedal (Adjusting)....9175
      Floor Pan Removal And Installation....9176
    CONTROL PEDALS AND LINKAGES (ACS)....9177
      Description....9177
      Pedal Removal And Installation....9177
      Linkage Removal And Installation....9178
      Pedal (Adjusting)....9178
      Floor Pan Removal And Installation....9179
    CONTROL PANEL....9181
      Description....9181
      Removal And Installation....9182
      Disassembly And Assembly....9183
      Linkage Removal And Installation....9185
      Pintle Arm Disassembly And Assembly....9189
      Linkage Neutral (Adjusting)....9190
      Linkage Travel (Adjusting)....9194
      Shock Removal And Installation....9198
    CONTROL PANEL (SJC)....9199
      Description....9199
      Removal And Installation....9199
    CONTROL HANDLE / LEVER....9201
      Description....9201
      Lever Removal And Installation....9201
      Boot Removal And Installation....9202
    CONTROL HANDLE / LEVER (ACS)....9203
      Description....9203
      Handle Sensor Removal And Installation....9203
      Handle Removal And Installation....9206
      Handle Disassembly And Assembly....9207
      Lever Removal And Installation....9207
      Boot Removal And Installation....9208
    CONTROL HANDLE / LEVER (SJC)....9209
      Description....9209
      Joystick Testing....9209
      Joystick Removal And Installation....9210
    ACCESS PANEL (INSIDE)....9211
      Removal And Installation (Left)....9211
      Removal And Installation (Right)....9211
    ACCESS PANEL (INSIDE) (SJC)....9213
      Removal And Installation (Left)....9213
      Removal And Installation (Right)....9213
    WINDOW (REAR)....9215
      Removal And Installation....9215
      Disassembly And Assembly....9215
    WINDOW (TOP)....9217
      Removal And Installation....9217
    WINDOW (SIDE)....9219
      Removal And Installation....9219
    CAB DOOR....9221
      Description....9221
      Removal And Installation....9221
      Disassembly And Assembly....9222
      Aligning....9223
      Adjusting....9224
      Checking Operation....9224
    ARMREST....9225
      Description....9225
      Removal And Installation....9226
      Disassembly And Assembly....9227
    LEFT SIDE LOWER PANEL....9231
      Removal And Installation....9231
      Disassembly And Assembly....9233
    RIGHT SIDE LOWER PANEL....9235
      Removal And Installation....9235
      Disassembly And Assembly....9236
    HEADLINER....9239
      Removal And Installation....9239
    FAN DUCT PANELS....9241
      Fan Duct Panels - Removal And Installation....9241
  ELECTRICAL SYSTEM & ANALYSIS....9243
    ELECTRICAL SCHEMATICS....9249
    ELECTRICAL SYSTEM INFORMATION....9287
      Glossary Of Electrical Symbols....9287
      Standard Cab Harness Connectors....9290
      Deluxe Cab Harness Connectors....9291
      Mainframe Harness Connectors - Manual Controls....9292
      Mainframe Harness Connectors - SJC....9293
      Engine Harness Connectors....9294
      Description....9295
      Troubleshooting....9296
      Fuse And Relay Location / Identification....9297
      Solenoid Testing....9299
    BATTERY....9301
      Removal And Installation....9301
      Servicing....9302
      Using A Booster Battery (Jump Starting)....9303
    ALTERNATOR....9305
      Belt Adjustment....9305
      Belt Replacement....9305
      Charging System Inspection....9306
      Alternator Voltage Testing....9307
      Low Voltage Testing....9307
      High Voltage Testing....9308
      Removal And Installation....9309
      Parts Identification....9311
    STARTER....9313
      Testing....9313
      Removal And Installation....9313
      Parts Identification....9314
    INSTRUMENT PANEL IDENTIFICATION....9315
      Left Panel....9315
      Display Screen....9317
      Right Panel (Standard Key Panel)....9318
      Right Panel (Keyless Start Panel)....9319
      Right Panel (Deluxe Instrumentation Panel)....9320
      Left Switch Panel....9322
      Right Switch Panel....9322
      Left Side Lower Panel....9323
      Right Side Lower Panel....9323
      Left Panel Removal And Installation....9324
      Right Panel (Standard Key Panel) Removal And Installation....9324
      Right Panel (Keyless Start Panel) Removal And Installation....9325
      Right Panel (Deluxe Instrumentation Panel) Removal And Installation....9325
      Key Switch Disassembly And Assembly....9326
      Alarm Disassembly And Assembly....9326
      Left Switch Panel Removal And Installation....9326
      Right Switch Panel Removal And Installation....9327
    LIGHTS....9329
      Front Removal And Installation....9329
      Rear Removal And Installation....9330
      Cab Light Removal And Installation....9330
    BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)....9331
      Description....9331
      Connector Identification....9332
      Removal And Installation....9338
    BOBCAT CONTROLLER (ACS)....9339
      Description....9339
      Connector And Wire Identification....9340
      Removal And Installation....9341
    BOBCAT CONTROLLER (SJC) (DRIVE)....9343
      Description....9343
      Connector Identification....9344
      Removal And Installation....9346
    ENGINE CONTROL UNIT (ECU)....9347
      Description....9347
      Cleaning....9348
      Removal And Installation....9349
    DIAGNOSTIC SERVICE CODES....9351
      Viewing Service Codes....9351
      Service Codes List....9352
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....9361
      Description....9361
      Inspecting The BICS (Engine STOPPED - Key ON)....9362
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....9362
      Inspecting The Seat Bar Sensor (Engine RUNNING)....9362
      Inspecting The Traction Lock (Engine RUNNING)....9362
      Inspecting The Lift Arm Bypass Control....9362
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....9362
      Troubleshooting....9363
    SEAT BAR SENSOR....9365
      Description....9365
      Troubleshooting....9365
      Testing....9366
      Removal And Installation....9367
      Bobcat Interlock Control System (BICS) Circuit Test....9370
    TRACTION LOCK....9373
      Description....9373
      Troubleshooting....9374
      Inspecting....9375
    CONTROL SYSTEM (ACS)....9377
      Description....9377
      Troubleshooting....9378
      Handle Sensor Connector Disassembly And Assembly....9379
      Switch Handle Removal....9380
      Switch Handle Installation....9382
      Actuator Connector Disassembly And Assembly....9385
      Handle Lock Solenoid Removal And Installation....9386
      Handle Lock Solenoid Disassembly And Assembly....9386
      Foot Sensor Removal And Installation....9387
      Foot Sensor Disassembly And Assembly....9388
      Foot Sensor Lock Solenoid Removal And Installation....9388
    ELECTRICAL / HYDRAULIC CONTROLS....9389
      Identification Chart....9389
      Description....9390
      Identification Chart ACD Group 0....9391
      Identification Chart ACD Group 1....9392
      Identification Chart ACD Group 2....9393
      Identification Chart ACD Group 3....9394
    ELECTRICAL / HYDRAULIC CONTROLS (ACS)....9395
      Identification Chart....9395
      Description....9396
      Identification Chart ACD Group 0....9397
      Identification Chart ACD Group 1....9398
      Identification Chart ACD Group 2....9399
      Identification Chart ACD Group 3....9400
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)....9401
      Identification Chart....9401
      Description....9402
      Identification Chart ACD Group 0....9403
      Identification Chart ACD Group 1....9404
      Identification Chart ACD Group 2....9405
      Identification Chart ACD Group 3....9406
    SERVICE PC (LAPTOP COMPUTER)....9407
      Connecting Remote Start Tool....9407
      Connecting Remote Start Tool (Service Tool)....9407
    CALIBRATION....9409
      Description....9409
      Actuator Testing....9409
      Lift And Tilt Calibration (SJC)....9412
      Hydrostatic Pump Calibration (SJC)....9414
      Lift And Tilt Calibration (ACS)....9419
    STEERING DRIFT COMPENSATION....9421
      Description....9421
      Operation....9421
    CONTROL PANEL SETUP....9423
      Right Panel Setup (Deluxe Instrumentation Panel)....9423
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....9427
      Password Description....9427
      Changing The Owner Password....9427
      Changing The User Passwords....9428
      Password Lockout Feature....9428
    PASSWORD SETUP (KEYLESS START PANEL)....9429
      Password Description....9429
      Changing The Owner Password....9429
      Password Lockout Feature....9429
    MAINTENANCE CLOCK....9431
      Description....9431
      Setup....9432
      Reset....9435
    BACK-UP ALARM SYSTEM....9437
      Description....9437
      Inspecting....9437
      Adjusting Switch Position....9438
      Troubleshooting (Standard And ACS)....9439
      Troubleshooting (Joystick)....9440
      Alarm Removal And Installation....9441
      Switch Removal And Installation....9441
    FRONT HORN....9443
      Removal And Installation....9443
      Troubleshooting....9444
      Troubleshooting (Joystick)....9445
    ENGINE SPEED CONTROL (HAND)....9447
      Removal And Installation....9447
    ENGINE SPEED CONTROL (FOOT)....9449
      Removal And Installation....9449
      Disassembly And Assembly....9450
  ENGINE SERVICE....9453
    ENGINE INFORMATION....9457
      Description....9457
      Specifications....9458
      Sensor Location....9460
      Torque Values....9466
      Troubleshooting....9468
      Engine Removal And Installation....9470
      Engine Mount Replacement....9479
    DIESEL OXIDATION CATALYST (DOC)....9481
      Removal And Installation....9481
    AIR CLEANER....9483
      Housing Removal And Installation....9483
    ENGINE COOLING SYSTEM....9485
      Radiator / Oil Cooler Removal And Installation....9485
      Hydraulic Fan Description....9488
      Fan Duct Removal And Installation....9488
      Hydraulic Fan Motor Assembly Removal And Installation....9489
      Hydraulic Fan Motor Removal And Installation....9490
      Hydraulic Fan Motor Disassembly And Assembly....9492
      Blower Housing Removal And Installation....9493
      Water Pump Removal And Installation....9494
      Thermostat Housing Removal And Installation....9495
      Testing The Thermostat....9496
    LUBRICATION SYSTEM....9497
      Description....9497
      Oil Pan Removal And Installation....9498
      Oil Pump Removal And Installation....9499
      Oil Pump Relief Valve Description....9500
      Oil Pump Relief Valve Removal And Installation....9500
      Oil Cooler Removal And Installation....9501
      Oil Filter Head Removal And Installation....9502
      Oil Cooler Bypass Description....9503
      Oil Cooler Bypass Removal And Installation....9503
    FUEL SYSTEM....9505
      Description....9505
      Transfer Pump / High Pressure Pump Removal And Installation....9506
      Fuel Cooler Removal And Installation....9509
      Fuel Injector Removal And Installation....9510
    CYLINDER HEAD....9513
      Glow Plugs Testing....9513
      Glow Plug Removal And Installation....9514
      Valve Clearance Adjustment....9515
      Cylinder Head Removal And Installation....9517
      Cylinder Head Disassembly And Assembly....9521
      Cylinder Head Inspection....9522
      Cylinder Head Top Clearance....9523
      Valve Step Height....9524
      Valve Stem Height....9524
      Valve Guide....9525
      Valve....9525
      Valve Spring....9526
      Rocker Arm Shaft Disassembly And Assembly....9527
      Rocker Arm Shaft Inspection....9528
      Push Rod Inspection....9528
    CRANKSHAFT AND PISTONS....9529
      Piston And Connecting Rod Removal And Installation....9529
      Piston And Connecting Rod Inspection....9530
      Crankshaft Removal And Installation....9532
      Cylinder Block Inspection....9535
      Crankshaft Inspection....9537
      Connecting Rod Inspection....9537
      Engine Component Class....9538
    CAMSHAFT....9541
      Removal And Installation....9541
      Inspecting....9542
    GEAR CASE....9545
      Gear Case Cover Removal And Installation....9545
      Gear Backlash....9546
      Gear Timing....9547
      Idle Gear Removal And Installation....9548
      Idle Gear Inspection....9548
    TURBOCHARGER....9549
      Description....9549
      Removal And Installation....9549
      Inspection....9551
    FLYWHEEL AND HOUSING....9553
      Flywheel Removal And Installation....9553
      Ring Gear Removal And Installation....9554
      Housing Removal And Installation....9554
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM....9555
      Description....9555
      Removal And Installation....9556
      Disassembly And Assembly....9560
  HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....9563
    AIR CONDITIONING SYSTEM FLOW....9565
      Description....9565
      Chart....9566
      Components....9567
      Safety Equipment....9570
    REGULAR MAINTENANCE....9571
      Filters....9571
      Belt Adjustment....9572
      Belt Replacement....9572
      Condenser....9572
      Air Conditioning Lubrication....9572
      Air Conditioning Service Chart....9573
      Evaporator / Heater Coil....9574
    TROUBLESHOOTING....9575
      Blower Motor Does Not Operate....9575
      Blower Motor Operates Normally, But Air Flow Is Insufficient....9575
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....9575
      The Compressor Does Not Operate At All, Or Operates Improperly....9575
      Gauge Pressure Related Troubleshooting....9576
      Troubleshooting Tree....9578
      Temperature / Pressure Chart....9582
      Poor A/C Performance....9584
      HVAC Repair And Leaks....9585
      Electrical System....9586
      Engine Coolant Bypassing The Heater Valve....9592
      Heater Valve Not Opening Or Closing....9593
    SYSTEM CHARGING AND RECLAMATION....9595
      Refrigerant Identification....9595
      Reclamation And Charging With Recovery / Charging Unit....9596
    COMPRESSOR....9599
      Removal And Installation....9599
      Oil....9601
      Oil Check....9602
    CONDENSER....9605
      Removal And Installation....9605
    RECEIVER / DRIER....9607
      Receiver / Drier Removal And Installation....9607
      Pressure Switch Removal And Installation....9609
      Schraeder Valve Removal And Installation....9610
    EVAPORATOR / HEATER UNIT....9611
      Removal And Installation....9611
    THERMOSTAT....9613
      Description....9613
      Removal And Installation....9614
    EXPANSION VALVE....9615
      Removal And Installation....9615
    EVAPORATOR COIL....9617
      Removal And Installation....9617
    HEATER COIL....9619
      Removal And Installation....9619
    BLOWER FAN....9621
      Removal And Installation....9621
      Disassembly And Assembly....9621
    HEATER VALVE....9625
      Removal And Installation....9625
    EVAPORATOR / HEATER COVER....9627
      Removing....9627
      Installing....9627
  SPECIFICATIONS....9629
    (T630) LOADER SPECIFICATIONS....9631
      Machine Dimensions....9631
      Performance....9632
      Engine....9632
      Drive System....9633
      Controls....9633
      Hydraulic System....9634
      Electrical System....9635
      Capacities....9635
      Tracks....9636
      Ground Pressure....9636
    TORQUE SPECIFICATIONS FOR BOLTS....9637
      Torque For General SAE Bolts....9637
      Torque For General Metric Bolts....9638
    HYDRAULIC CONNECTION SPECIFICATIONS....9639
      Straight Thread O-ring Fitting....9639
      Flare Fitting....9640
      Tubelines And Hoses....9640
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....9641
      Specifications....9641
    CONVERSIONS....9643
      Decimal And Millimeter Equivalent Chart....9643
      U.S. To Metric Conversion Chart....9643
    SERVICE TOOLS REQUIRED....9645
      Remote Start Tools....9645
      Hydraulic Tools....9646
      Mainframe And Drive Tools....9648
      Electrical Tools....9649
      Engine Tools....9649
      HVAC Tools....9653
  ALPHABETICAL INDEX....9655
6990755 (12-14) - T650 Compact Track Loader Service Manual....9659
  MAINTENANCE SAFETY....9661
  CONTENTS....9663
  FOREWORD....9665
    FOREWORD....9667
    SAFETY INSTRUCTIONS....9669
    FIRE PREVENTION....9671
      Maintenance....9671
      Operation....9671
      Electrical....9671
      Hydraulic System....9671
      Fueling....9671
      Starting....9671
      Spark Arrester Exhaust System....9671
      Welding And Grinding....9672
      Fire Extinguishers....9672
    SERIAL NUMBER LOCATIONS....9673
      Loader Serial Number....9673
      Engine Serial Number....9673
    DELIVERY REPORT....9674
    LOADER IDENTIFICATION....9675
  SAFETY & MAINTENANCE....9677
    LIFTING AND BLOCKING THE LOADER....9681
      Procedure....9681
    LIFT ARM SUPPORT DEVICE....9683
      Description....9683
      Installing....9684
      Removing....9685
    OPERATOR CAB....9687
      Description....9687
      Raising....9688
      Lowering....9689
      Cab Door Sensor....9690
      Special Applications Kit....9691
      Special Applications Kit Inspection And Maintenance....9691
      Forestry Door And Window Kit....9692
      Forestry Door And Window Kit Inspection And Maintenance....9692
    TRANSPORTING THE LOADER ON A TRAILER....9693
      Loading And Unloading....9693
      Fastening....9693
    TOWING THE LOADER....9695
      Procedure....9695
    REMOTE START TOOL KIT-MEL1563....9697
      Remote Start Tool - MEL1563....9697
      Service Tool Harness Communicator - MEL1566....9699
      Remote Start Procedure....9699
    REMOTE START TOOL (SERVICE TOOL) KIT - 7217666....9703
      Description....9703
      Remote Start Tool (Service Tool) - 7022042....9704
      Loader Service Tool Harness - 6689747....9705
      Computer Service Tool Harness - 6689746....9706
      Remote Start Procedure....9707
    SERVICE SCHEDULE....9711
      Maintenance Intervals....9711
    AIR CLEANER SERVICE....9713
      Replacing Filter Elements....9713
    ENGINE COOLING SYSTEM....9715
      Maintenance Platform....9715
      Cleaning....9715
      Checking Level....9718
      Removing And Replacing Coolant....9719
    FUEL SYSTEM....9721
      Fuel Specifications....9721
      Biodiesel Blend Fuel....9721
      Filling The Fuel Tank....9722
      Fuel Filter....9723
      Removing Air From The Fuel System....9724
    ENGINE LUBRICATION SYSTEM....9727
      Checking And Adding Engine Oil....9727
      Engine Oil Chart....9727
      Removing And Replacing Oil And Filter....9728
    HYDRAULIC / HYDROSTATIC SYSTEM....9731
      Checking And Adding Fluid....9731
      Hydraulic / Hydrostatic Fluid Chart....9731
      Removing And Replacing Hydraulic Fluid....9732
      Removing And Replacing Hydraulic / Hydrostatic Filter....9734
      Removing And Replacing Hydraulic Charge Filter....9735
      Replacing Reservoir Breather Cap....9736
    BOB-TACH (HAND LEVER)....9737
      Inspection And Maintenance....9737
    BOB-TACH (POWER)....9739
      Inspection And Maintenance....9739
    LUBRICATING THE LOADER....9741
      Lubrication Locations....9741
    TRACK ROLLER AND IDLER LUBRICATION....9744
      Description....9744
    PIVOT PINS....9744
      Inspection And Maintenance....9744
    PIVOT PINS....9745
      Inspection And Maintenance....9745
    LOADER STORAGE AND RETURN TO SERVICE....9747
      Storage....9747
      Return To Service....9747
    STOPPING THE ENGINE AND LEAVING THE LOADER....9749
      Procedure....9749
    EMERGENCY EXIT....9751
      Rear Window Identification....9751
      Rear Window Removal (Latches)....9751
      Rear Window Removal (Rubber Cord)....9751
      External Access (Rear Window With Latches)....9752
      External Access (Rear Window With Rubber Cord)....9752
      Front Door....9752
    SEAT BELT....9755
      Inspection And Maintenance....9755
  HYDRAULIC SYSTEM....9757
    HYDRAULIC/HYDROSTATIC SCHEMATICS....9761
    HYDRAULIC SYSTEM INFORMATION....9769
      Glossary Of Hydraulic / Hydrostatic Symbols....9769
      Troubleshooting....9773
    CYLINDER (LIFT)....9775
      Testing....9775
      Removal And Installation....9776
      Parts Identification....9780
      Disassembly....9781
      Assembly....9782
    CYLINDER (TILT)....9785
      Testing....9785
      Removal And Installation....9786
      Base End Pivot Pin Removal And Installation....9788
      Disassembly....9789
      Assembly....9791
    CYLINDER (BOB-TACH)....9795
      Testing....9795
      Removal And Installation....9796
      Parts Identification....9797
      Disassembly....9798
      Assembly....9799
    MAIN RELIEF VALVE....9803
      Description....9803
      Testing....9804
      Main Relief Valve Adjustment....9806
      Main Relief Valve Removal And Installation....9806
      Auxiliary Relief Valve Adjustment....9807
      Auxiliary Relief Valve Removal And Installation....9808
    HYDRAULIC CONTROL VALVE (STANDARD)....9809
      Description....9809
      Removal And Installation....9810
      Mount Bracket Removal And Installation....9814
      Identification Chart....9815
      Lift Load Check Valve Removal And Installation....9816
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....9817
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....9818
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....9818
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....9819
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....9819
      Port Relief Valve Removal And Installation....9820
      Plug Removal And Installation....9822
      Rubber Boot Removal And Installation....9823
      End Cap Block Removal And Installation....9823
      Lift Spool And Detent Removal And Installation....9824
      Tilt Spool Removal And Installation....9832
      Auxiliary Spool Removal And Installation....9834
      Auxiliary Solenoid Removal And Installation....9835
      Solenoid Removal And Installation....9836
      Lock Valve Removal And Installation....9837
      Lift Arm Bypass Orifice Removal And Installation....9839
      Main Relief Valve Removal And Installation....9839
      Auxiliary Relief Valve Removal And Installation....9840
      Check Valve Removal And Installation....9840
    HYDRAULIC CONTROL VALVE (ACS) OR (SJC)....9843
      Description....9843
      Removal And Installation....9843
      Actuator Removal And Installation (In Loader)....9848
      Actuator Removal And Installation (Out Of Loader)....9849
      Identification Chart....9852
      Mount Bracket Removal And Installation....9853
      Lift Load Check Valve Removal And Installation....9853
      Load Check Valve Removal And Installation (Tilt And Auxiliary)....9854
      Anti-Cavitation Valve Removal And Installation (Lift, Rod End)....9855
      Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)....9855
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)....9856
      Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....9856
      Port Relief Valve Removal And Installation....9857
      Plug Removal And Installation....9859
      End Cap Block Removal And Installation....9860
      Lift Spool Removal And Installation....9860
      Lift Spool Disassembly And Assembly....9862
      Tilt Spool Removal And Installation....9863
      Tilt Spool Disassembly And Assembly....9864
      Auxiliary Spool Removal And Installation....9865
      Auxiliary Solenoid Removal And Installation....9866
      Solenoid Removal And Installation....9867
      Lock Valve Removal And Installation....9868
      Lift Arm Bypass Orifice Removal And Installation....9870
      Main Relief Valve Removal And Installation....9870
      Auxiliary Relief Valve Removal And Installation....9871
      Check Valve Removal And Installation....9871
    LIFT ARM BYPASS CONTROL VALVE....9873
      Description....9873
      Removal And Installation....9874
      Bracket Removal And Installation....9875
      Disassembly And Assembly....9875
    HYDRAULIC PUMP....9877
      Description....9877
      Pump Test At Quick Couplers....9877
      Direct Pump Test (Standard Section)....9878
      Direct Pump Test (Charge Section)....9880
      Removal And Installation....9882
      Hydraulic Pump Startup....9884
      Parts Identification....9885
      Disassembly And Assembly....9886
    HYDRAULIC PUMP (HIGH FLOW)....9887
      Description....9887
      Pump Test At Quick Couplers....9887
      Direct Pump Test (Standard Section)....9888
      Direct Pump Test (Charge Section)....9889
      Direct Pump Test (High Flow Section)....9891
      High Flow Relief Valve Adjustment....9893
      High Flow Relief Valve Removal And Installation....9894
      Solenoid Removal And Installation....9895
      Removal And Installation....9896
      Hydraulic Pump Startup....9898
      Parts Identification....9899
      Disassembly And Assembly....9900
    HYDRAULIC / HYDROSTATIC FILTERS....9901
      Description....9901
      Housing Removal And Installation....9901
    HYDRAULIC FLUID RESERVOIR....9903
      Description....9903
      Removal And Installation....9903
      Hydraulic Fluid Screen....9904
    OIL COOLER....9905
      Description....9905
      Removal And Installation....9905
    BUCKET POSITION VALVE....9907
      Description....9907
      Solenoid Removal And Installation....9907
      Solenoid Testing....9908
      Removal And Installation....9908
      Disassembly And Assembly....9911
    REAR AUXILIARY DIVERTER VALVE....9913
      Description....9913
      Solenoid Testing....9913
      Removal And Installation....9914
      Disassembly And Assembly....9915
    BOB-TACH (POWER) BLOCK....9921
      Description....9921
      Removal And Installation....9921
      Disassembly And Assembly....9923
    FRONT AUXILIARY HYDRAULIC COUPLER BLOCK....9933
      Description....9933
      Removal And Installation....9933
      Disassembly And Assembly....9933
  HYDROSTATIC SYSTEM....9935
    HYDROSTATIC SYSTEM INFORMATION....9937
      Description....9937
      Troubleshooting....9938
    HYDROSTATIC DRIVE MOTOR....9939
      Description....9939
      Removing And Replacing Fluid....9939
      Removal And Installation....9940
      Parts Identification....9942
      Disassembly And Assembly....9944
    HYDROSTATIC DRIVE MOTOR (TWO-SPEED)....9957
      Description....9957
      Removing And Replacing Fluid....9957
      Removal And Installation....9958
      Parts Identification....9960
      Disassembly And Assembly....9962
    CHARGE PRESSURE....9975
      Description....9975
      Testing....9975
      Sender Removal And Installation....9977
      Adjusting....9978
    HYDROSTATIC PUMP....9981
      Description....9981
      Removal And Installation....9982
      Hydrostatic Pump Startup....9983
      Replenishing / High Pressure Relief Valve Removal And Installation....9983
      Parts Identification (Left Half)....9984
      Parts Identification (Right Half)....9985
      Disassembly....9986
      Assembly....9993
    HYDROSTATIC PUMP (SJC)....9999
      Description....9999
      Hydraulic Controller Removal And Installation....10000
      Removal And Installation....10002
      Hydrostatic Pump Start Up....10003
      Parts Identification....10004
      High Pressure Relief And Bypass Valve....10005
      Charge Relief Valve....10006
      Disassembly And Assembly....10007
      Mechanical Neutral Adjustment....10020
      Hydraulic Controller Neutral Adjustment....10023
    DRIVE BELT....10027
      Belt Adjustment....10027
      Stop Adjustment....10027
      Belt Replacement....10028
      Tensioner Pulley Removal And Installation....10030
      Tensioner Pulley Disassembly And Assembly....10030
    TWO-SPEED / BRAKE VALVE....10031
      Description....10031
      Valve Block Removal And Installation....10032
      Valve Block Disassembly And Assembly....10034
    DRAIN MANIFOLD....10037
      Description....10037
      Drain Manifold Removal And Installation....10037
  DRIVE SYSTEM....10039
    BRAKE....10041
      Description....10041
      Block Removal And Installation....10041
      Block Disassembly And Assembly....10042
    BRAKE (TWO-SPEED)....10045
      Description....10045
    TRACK UNDERCARRIAGE COMPONENTS (SOLID- MOUNTED)....10047
      Description....10047
      Checking Tension....10048
      Adjusting Tension....10049
      Track Removal And Installation....10050
      Idler (Front) Removal And Installation....10052
      Track Tensioner Disassembly And Assembly....10055
      Idler (Rear) Removal And Installation....10057
      Roller Removal And Installation....10057
      Sprocket Removal And Installation (Single Speed)....10058
      Sprocket Removal And Installation (Two Speed)....10058
      Track Housing Removal And Installation....10059
    TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION)....10061
      Description....10061
      Checking Tension....10062
      Adjusting Tension....10063
      Track Removal And Installation....10064
      Idler (Front) Removal And Installation....10066
      Track Tensioner Disassembly And Assembly....10069
      Idler (Rear) Removal And Installation....10071
      Roller Removal And Installation....10071
      Leaf Spring Removal And Installation....10072
      Sprocket Removal And Installation (Single Speed)....10073
      Sprocket Removal And Installation (Two Speed)....10073
      Track Housing Removal And Installation....10074
    TRACK MAINTENANCE....10075
      Track Damage Identification....10075
  MAINFRAME....10087
    SEAT BAR....10091
      Description....10091
      Removal And Installation....10091
      Disassembly And Assembly....10092
      Compression Spring Disassembly And Assembly....10093
    OPERATOR CAB....10095
      Gas Spring Removal And Installation....10095
      Gas Spring Bracket Disassembly And Assembly....10096
      Removal And Installation....10096
    OPERATOR SEAT....10099
      Removal And Installation....10099
      Seat Belt Removal And Installation (Retractable)....10099
      Seat Belt And Bracket Removal And Installation (Standard)....10100
      Seat Belt Bracket Removal And Installation....10100
    OPERATOR SEAT (SUSPENSION)....10101
      Removal And Installation....10101
      Slide Rail Removal And Installation....10101
      Seat Belt Removal And Installation....10102
      Lower Cushion Removal....10102
      Lower Cushion Installation....10103
      Back Cushion Removal And Installation....10103
      Shock Removal And Installation....10104
      3-Point Seat Belt Removal And Installation....10104
    BOB-TACH (HAND LEVER)....10107
      Description....10107
      Removal And Installation....10107
      Lever And Wedge Disassembly And Assembly....10109
      Pivot Pin Bushing And Seal Removal And Installation....10111
    BOB-TACH (POWER)....10113
      Description....10113
      Removal And Installation....10113
      Lever And Wedge Disassembly And Assembly....10116
      Pivot Pin Bushing And Seal Removal And Installation....10117
    LIFT ARMS....10119
      Stabilizer Bar Removal And Installation....10119
      Link Removal And Installation....10120
      Removal And Installation....10121
    REAR GRILLE....10125
      Removing....10125
      Installing....10126
      Shield Removal And Installation....10127
    REAR DOOR (TAILGATE)....10129
      Removal And Installation....10129
      Striker Removal And Installation....10130
      Striker Disassembly And Assembly....10130
      Striker (Adjusting)....10130
      Latch Removal And Installation....10131
    FUEL TANK....10133
      Removal And Installation....10133
      Fuel Level Sender Removal And Installation....10135
      Fuel Fill Screen Removal And Installation....10135
    CONTROL PEDALS AND LINKAGES....10137
      Description....10137
      Pedal Removal And Installation....10137
      Linkage Removal And Installation....10138
      Pedal (Adjusting)....10139
      Floor Pan Removal And Installation....10140
    CONTROL PEDALS AND LINKAGES (ACS)....10141
      Description....10141
      Pedal Removal And Installation....10141
      Linkage Removal And Installation....10142
      Pedal (Adjusting)....10142
      Floor Pan Removal And Installation....10143
    CONTROL PANEL....10145
      Description....10145
      Removal And Installation....10146
      Disassembly And Assembly....10147
      Linkage Removal And Installation....10149
      Pintle Arm Disassembly And Assembly....10153
      Linkage Neutral (Adjusting)....10154
      Linkage Travel (Adjusting)....10158
      Shock Removal And Installation....10162
    CONTROL PANEL (SJC)....10163
      Description....10163
      Removal And Installation....10163
    CONTROL HANDLE / LEVER....10165
      Description....10165
      Lever Removal And Installation....10165
      Boot Removal And Installation....10166
    CONTROL HANDLE / LEVER (ACS)....10167
      Description....10167
      Handle Sensor Removal And Installation....10167
      Handle Removal And Installation....10170
      Handle Disassembly And Assembly....10171
      Lever Removal And Installation....10171
      Boot Removal And Installation....10172
    CONTROL HANDLE / LEVER (SJC)....10173
      Description....10173
      Joystick Testing....10173
      Joystick Removal And Installation....10174
    ACCESS PANEL (INSIDE)....10175
      Removal And Installation (Left)....10175
      Removal And Installation (Right)....10175
    ACCESS PANEL (INSIDE) (SJC)....10177
      Removal And Installation (Left)....10177
      Removal And Installation (Right)....10177
    WINDOW (REAR)....10179
      Removal And Installation....10179
      Disassembly And Assembly....10179
    WINDOW (TOP)....10181
      Removal And Installation....10181
    WINDOW (SIDE)....10183
      Removal And Installation....10183
    CAB DOOR....10185
      Description....10185
      Removal And Installation....10185
      Disassembly And Assembly....10186
      Aligning....10187
      Adjusting....10188
      Checking Operation....10188
    ARMREST....10189
      Description....10189
      Removal And Installation....10190
      Disassembly And Assembly....10191
    LEFT SIDE LOWER PANEL....10195
      Removal And Installation....10195
      Disassembly And Assembly....10197
    RIGHT SIDE LOWER PANEL....10199
      Removal And Installation....10199
      Disassembly And Assembly....10200
    HEADLINER....10203
      Removal And Installation....10203
    FAN DUCT PANELS....10205
      Fan Duct Panels - Removal And Installation....10205
  ELECTRICAL SYSTEM & ANALYSIS....10207
    ELECTRICAL SCHEMATICS....10213
    ELECTRICAL SYSTEM INFORMATION....10251
      Glossary Of Electrical Symbols....10251
      Standard Cab Harness Connectors....10254
      Deluxe Cab Harness Connectors....10255
      Mainframe Harness Connectors - Manual Controls....10256
      Mainframe Harness Connectors - SJC....10257
      Engine Harness Connectors....10258
      Description....10259
      Troubleshooting....10260
      Fuse And Relay Location / Identification....10261
      Solenoid Testing....10263
    BATTERY....10265
      Removal And Installation....10265
      Servicing....10266
      Using A Booster Battery (Jump Starting)....10267
    ALTERNATOR....10269
      Belt Adjustment....10269
      Belt Replacement....10269
      Charging System Inspection....10270
      Alternator Voltage Testing....10271
      Low Voltage Testing....10271
      High Voltage Testing....10272
      Removal And Installation....10273
      Parts Identification....10275
    STARTER....10277
      Testing....10277
      Removal And Installation....10277
      Parts Identification....10278
    INSTRUMENT PANEL IDENTIFICATION....10279
      Left Panel....10279
      Display Screen....10281
      Right Panel (Standard Key Panel)....10282
      Right Panel (Keyless Start Panel)....10283
      Right Panel (Deluxe Instrumentation Panel)....10284
      Left Switch Panel....10286
      Right Switch Panel....10286
      Left Side Lower Panel....10287
      Right Side Lower Panel....10287
      Left Panel Removal And Installation....10288
      Right Panel (Standard Key Panel) Removal And Installation....10288
      Right Panel (Keyless Start Panel) Removal And Installation....10289
      Right Panel (Deluxe Instrumentation Panel) Removal And Installation....10289
      Key Switch Disassembly And Assembly....10290
      Alarm Disassembly And Assembly....10290
      Left Switch Panel Removal And Installation....10290
      Right Switch Panel Removal And Installation....10291
    LIGHTS....10293
      Front Removal And Installation....10293
      Rear Removal And Installation....10294
      Cab Light Removal And Installation....10294
    BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)....10295
      Description....10295
      Connector Identification....10296
      Removal And Installation....10302
    BOBCAT CONTROLLER (ACS)....10303
      Description....10303
      Connector And Wire Identification....10304
      Removal And Installation....10305
    BOBCAT CONTROLLER (SJC) (DRIVE)....10307
      Description....10307
      Connector Identification....10308
      Removal And Installation....10310
    ENGINE CONTROL UNIT (ECU)....10311
      Description....10311
      Cleaning....10312
      Removal And Installation....10313
    DIAGNOSTIC SERVICE CODES....10315
      Viewing Service Codes....10315
      Service Codes List....10316
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)....10325
      Description....10325
      Inspecting The BICS (Engine STOPPED - Key ON)....10326
      Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....10326
      Inspecting The Seat Bar Sensor (Engine RUNNING)....10326
      Inspecting The Traction Lock (Engine RUNNING)....10326
      Inspecting The Lift Arm Bypass Control....10326
      Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)....10326
      Troubleshooting....10327
    SEAT BAR SENSOR....10329
      Description....10329
      Troubleshooting....10329
      Testing....10330
      Removal And Installation....10331
      Bobcat Interlock Control System (BICS) Circuit Test....10334
    TRACTION LOCK....10337
      Description....10337
      Troubleshooting....10338
      Inspecting....10339
    CONTROL SYSTEM (ACS)....10341
      Description....10341
      Troubleshooting....10342
      Handle Sensor Connector Disassembly And Assembly....10343
      Switch Handle Removal....10344
      Switch Handle Installation....10346
      Actuator Connector Disassembly And Assembly....10349
      Handle Lock Solenoid Removal And Installation....10350
      Handle Lock Solenoid Disassembly And Assembly....10350
      Foot Sensor Removal And Installation....10351
      Foot Sensor Disassembly And Assembly....10352
      Foot Sensor Lock Solenoid Removal And Installation....10352
    ELECTRICAL / HYDRAULIC CONTROLS....10353
      Identification Chart....10353
      Description....10354
      Identification Chart ACD Group 0....10355
      Identification Chart ACD Group 1....10356
      Identification Chart ACD Group 2....10357
      Identification Chart ACD Group 3....10358
    ELECTRICAL / HYDRAULIC CONTROLS (ACS)....10359
      Identification Chart....10359
      Description....10360
      Identification Chart ACD Group 0....10361
      Identification Chart ACD Group 1....10362
      Identification Chart ACD Group 2....10363
      Identification Chart ACD Group 3....10364
    ELECTRICAL / HYDRAULIC CONTROLS (SJC)....10365
      Identification Chart....10365
      Description....10366
      Identification Chart ACD Group 0....10367
      Identification Chart ACD Group 1....10368
      Identification Chart ACD Group 2....10369
      Identification Chart ACD Group 3....10370
    SERVICE PC (LAPTOP COMPUTER)....10371
      Connecting Remote Start Tool....10371
      Connecting Remote Start Tool (Service Tool)....10371
    CALIBRATION....10373
      Description....10373
      Actuator Testing....10373
      Lift And Tilt Calibration (SJC)....10376
      Hydrostatic Pump Calibration (SJC)....10378
      Lift And Tilt Calibration (ACS)....10383
    STEERING DRIFT COMPENSATION....10385
      Description....10385
      Operation....10385
    CONTROL PANEL SETUP....10387
      Right Panel Setup (Deluxe Instrumentation Panel)....10387
    PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....10391
      Password Description....10391
      Changing The Owner Password....10391
      Changing The User Passwords....10392
      Password Lockout Feature....10392
    PASSWORD SETUP (KEYLESS START PANEL)....10393
      Password Description....10393
      Changing The Owner Password....10393
      Password Lockout Feature....10393
    MAINTENANCE CLOCK....10395
      Description....10395
      Setup....10396
      Reset....10399
    BACK-UP ALARM SYSTEM....10401
      Description....10401
      Inspecting....10401
      Adjusting Switch Position....10402
      Troubleshooting (Standard And ACS)....10403
      Troubleshooting (Joystick)....10404
      Alarm Removal And Installation....10405
      Switch Removal And Installation....10405
    FRONT HORN....10407
      Removal And Installation....10407
      Troubleshooting....10408
      Troubleshooting (Joystick)....10409
    ENGINE SPEED CONTROL (HAND)....10411
      Removal And Installation....10411
    ENGINE SPEED CONTROL (FOOT)....10413
      Removal And Installation....10413
      Disassembly And Assembly....10414
  ENGINE SERVICE....10417
    ENGINE INFORMATION....10421
      Description....10421
      Specifications....10422
      Sensor Location....10424
      Torque Values....10430
      Troubleshooting....10432
      Engine Removal And Installation....10434
      Engine Mount Replacement....10443
    DIESEL OXIDATION CATALYST (DOC)....10445
      Removal And Installation....10445
    AIR CLEANER....10447
      Housing Removal And Installation....10447
    ENGINE COOLING SYSTEM....10449
      Radiator / Oil Cooler Removal And Installation....10449
      Hydraulic Fan Description....10452
      Fan Duct Removal And Installation....10452
      Hydraulic Fan Motor Assembly Removal And Installation....10453
      Hydraulic Fan Motor Removal And Installation....10454
      Hydraulic Fan Motor Disassembly And Assembly....10456
      Blower Housing Removal And Installation....10457
      Water Pump Removal And Installation....10458
      Thermostat Housing Removal And Installation....10459
      Testing The Thermostat....10460
    LUBRICATION SYSTEM....10461
      Description....10461
      Oil Pan Removal And Installation....10462
      Oil Pump Removal And Installation....10463
      Oil Pump Relief Valve Description....10464
      Oil Pump Relief Valve Removal And Installation....10464
      Oil Cooler Removal And Installation....10465
      Oil Filter Head Removal And Installation....10466
      Oil Cooler Bypass Description....10467
      Oil Cooler Bypass Removal And Installation....10467
    FUEL SYSTEM....10469
      Description....10469
      Transfer Pump / High Pressure Pump Removal And Installation....10470
      Fuel Cooler Removal And Installation....10473
      Fuel Injector Removal And Installation....10474
    CYLINDER HEAD....10477
      Glow Plugs Testing....10477
      Glow Plug Removal And Installation....10478
      Valve Clearance Adjustment....10479
      Cylinder Head Removal And Installation....10481
      Cylinder Head Disassembly And Assembly....10485
      Cylinder Head Inspection....10486
      Cylinder Head Top Clearance....10487
      Valve Step Height....10488
      Valve Stem Height....10488
      Valve Guide....10489
      Valve....10489
      Valve Spring....10490
      Rocker Arm Shaft Disassembly And Assembly....10491
      Rocker Arm Shaft Inspection....10492
      Push Rod Inspection....10492
    CRANKSHAFT AND PISTONS....10493
      Piston And Connecting Rod Removal And Installation....10493
      Piston And Connecting Rod Inspection....10494
      Crankshaft Removal And Installation....10496
      Cylinder Block Inspection....10499
      Crankshaft Inspection....10501
      Connecting Rod Inspection....10501
      Engine Component Class....10502
    CAMSHAFT....10505
      Removal And Installation....10505
      Inspecting....10506
    GEAR CASE....10509
      Gear Case Cover Removal And Installation....10509
      Gear Backlash....10510
      Gear Timing....10511
      Idle Gear Removal And Installation....10512
      Idle Gear Inspection....10512
    TURBOCHARGER....10513
      Description....10513
      Removal And Installation....10513
      Inspection....10515
    FLYWHEEL AND HOUSING....10517
      Flywheel Removal And Installation....10517
      Ring Gear Removal And Installation....10518
      Housing Removal And Installation....10518
    EXHAUST GAS RECIRCULATION (EGR) SYSTEM....10519
      Description....10519
      Removal And Installation....10520
      Disassembly And Assembly....10524
  HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....10527
    AIR CONDITIONING SYSTEM FLOW....10529
      Description....10529
      Chart....10530
      Components....10531
      Safety Equipment....10534
    REGULAR MAINTENANCE....10535
      Filters....10535
      Belt Adjustment....10536
      Belt Replacement....10536
      Condenser....10536
      Air Conditioning Lubrication....10536
      Air Conditioning Service Chart....10537
      Evaporator / Heater Coil....10538
    TROUBLESHOOTING....10539
      Blower Motor Does Not Operate....10539
      Blower Motor Operates Normally, But Air Flow Is Insufficient....10539
      Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....10539
      The Compressor Does Not Operate At All, Or Operates Improperly....10539
      Gauge Pressure Related Troubleshooting....10540
      Troubleshooting Tree....10542
      Temperature / Pressure Chart....10546
      Poor A/C Performance....10548
      HVAC Repair And Leaks....10549
      Electrical System....10550
      Engine Coolant Bypassing The Heater Valve....10556
      Heater Valve Not Opening Or Closing....10557
    SYSTEM CHARGING AND RECLAMATION....10559
      Refrigerant Identification....10559
      Reclamation And Charging With Recovery / Charging Unit....10560
    COMPRESSOR....10563
      Removal And Installation....10563
      Oil....10565
      Oil Check....10566
    CONDENSER....10569
      Removal And Installation....10569
    RECEIVER / DRIER....10571
      Receiver / Drier Removal And Installation....10571
      Pressure Switch Removal And Installation....10573
      Schraeder Valve Removal And Installation....10574
      Removal And Installation....10575
    THERMOSTAT....10577
      Description....10577
      Removal And Installation....10578
      Removal And Installation....10579
      Removal And Installation....10581
      Removal And Installation....10583
    BLOWER FAN....10585
      Removal And Installation....10585
      Disassembly And Assembly....10585
      Removal And Installation....10589
    EVAPORATOR / HEATER COVER....10591
      Removing....10591
      Installing....10591
  SPECIFICATIONS....10593
    (T650) LOADER SPECIFICATIONS....10595
      Machine Dimensions....10595
      Performance....10596
      Engine....10596
      Drive System....10597
      Controls....10597
      Hydraulic System....10598
      Electrical System....10599
      Capacities....10599
      Tracks....10600
      Ground Pressure....10600
    TORQUE SPECIFICATIONS FOR BOLTS....10601
      Torque For General SAE Bolts....10601
      Torque For General Metric Bolts....10602
    HYDRAULIC CONNECTION SPECIFICATIONS....10603
      Straight Thread O-ring Fitting....10603
      Flare Fitting....10604
      Tubelines And Hoses....10604
    HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS....10605
      Specifications....10605
    CONVERSIONS....10607
      Decimal And Millimeter Equivalent Chart....10607
      U.S. To Metric Conversion Chart....10607
    SERVICE TOOLS REQUIRED....10609
      Remote Start Tools....10609
      Hydraulic Tools....10610
      Mainframe And Drive Tools....10612
      Electrical Tools....10613
      Engine Tools....10613
      HVAC Tools....10617
  ALPHABETICAL INDEX....10619