Bobcat T3571, T3571L Telescopic Handlers Repair Service Manuals
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Model:
Complete repair service manual with Electrical Wiring Diagrams for Bobcat T3571, T3571L Telescopic Handlers, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Bobcat T3571, T3571L Telescopic Handlers 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.
6989559 (2-10) - T3571(L) Telescopic Handler Operation & Maintenance Manual.pdf
6986765 (8-12) - T3571, T3571L Telescopic Handler Service Manual.pdf
6986765 (2-10) - T3571, T3571L Telescopic Handler Service Manual.pdf
4852150 (10-12) - T3571, T3571L Service Manual.pdf
4852150 (7-06) - T3571, T3571L Service Manual.pdf
Total Pages: 2,212 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
4852150 (10-12) - T3571, T3571L Service Manual...1
MAINTENANCE SAFETY...3
ALPHABETICAL INDEX...5
CONTENTS...7
FOREWORD...8
SAFETY INSTRUCTIONS...11
Before Operation...11
Safe Operation Is The Operator’s Responsibility...12
Safe Operation Needs A Qualified Operator...12
A Qualified Operator Must Do The Following:...12
SERIAL NUMBER LOCATIONS...13
Telescopic Handler Serial Number...13
Engine Serial Number...13
Other Serial Numbers...13
Delivery Report...13
Identification Of The Telescopic Handler...14
SAFETY AND MAINTENANCE...15
LIFTING AND BLOCKING THE TELESCOPIC HANDLER...17
Procedure...17
OPERATOR CAB...19
Emergency Exit...19
Cab Door...20
Cab Door Window...20
TRANSPORTING THE Telescopic Handler...21
Procedure...21
TOWING THE Telescopic Handler...23
Preparing for towing...23
Disengaging the hydrostatic transmission...23
Releasing the handbrake (For S/N 362811001 - 362812000, S/N 362911001 - 368012000):...24
Releasing the handbrake (For S/N 362812001 and Above, S/N 362912001 and Above):...24
Towing the Telescopic Handler...25
SERVICE SCHEDULE...27
AIR CLEANER SERVICE...29
Replacing Filter Element...29
ENGINE COOLING SYSTEM...31
Cleaning The Cooling System...31
Checking The Coolant Level...31
Replacing The Coolant...32
FUEL SYSTEM...33
Fuel Specificaitons...33
Fuel Filter...33
ENGINE LUBRICATION SYSTEM...35
Checking Engine Oil...35
Oil Chart...35
Replacing Oil And Filter...36
HYDRAULIC/HYDROSTATIC SYSTEM...37
Checking And Adding Fluid...37
Replacing Hydraulic/Hydrostatic Filter...38
Replacing Hydraulic Fluid...39
AXLES (FRONT AND REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...41
Checking Oil Level (Planetary Carrier)...41
Draining Oil (Planetary Carrier)...41
Checking Oil Level (Rear Differential)...42
Draining Oil (Rear Differential)...42
Checking Oil Level (Front Differential)...42
Draining Oil (Front Differential)...42
AXLES (FRONT AND REAR) (For S/N 362812001 and Above, S/N 362912001 and Above)...43
Checking Oil Level (Planetary Carrier)...43
Draining Oil (Planetary Carrier)...43
Checking Oil Level (Rear Differential)...44
Draining Oil (Rear Differential)...44
Checking Oil Level (Front Differential)...44
Draining Oil (Front Differential)...45
LUBRICATION (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...47
Procedure...47
LUBRICATION (For S/N 362812001 and Above, S/N 362912001 and Above)...53
Procedure...53
TIRE MAINTENANCE...59
Wheel Nuts...59
Tire Rotation...59
Tire Mounting...59
SPARK ARRESTOR MUFFLER...61
Cleaning...61
OPTIONAL APPROVED BOOM STOP...63
Installing The Approved Boom Stop...63
Removing The Approved Boom Stop...63
ENGINE COVER...65
Opening And Closing The Engine Cover...65
HYDRAULIC SYSTEM...67
HYDRAULIC SYSTEM INFORMATION...71
Troubleshooting Chart...74
Tightening Procedures...75
LIFT CYLINDER...77
Removal And Installation...77
Parts Identification...81
Disassembly...82
Assembly...87
BUCKET POSITIONING CYLINDER...93
Removal And Installation...93
Parts Identification...96
Disassembly...97
Assembly...101
EXTENSION CYLINDER...105
Cylinder Group Removal And Installation...105
Upper Tubeline Removal...107
Upper Tubeline Installation...107
Extension Cylinder Removal And Installation...109
Tubeline Tray Disassembly...111
Tubeline Tray Assembly...113
Parts Identification...117
Disassembly...118
Assembly...122
TILT CYLINDER...127
Removal And Installation...127
Parts Identification...128
Disassembly...129
Assembly...133
STEERING CYLINDER (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...137
Removal And Installation...137
Parts Identification...139
Disassembly...140
Assembly...143
Parts Identification...139
STEERING CYLINDER (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above)...149
Removing The Steering Cylinder...149
Installing The Steering Cylinder...151
Disassembling The Steering Cylinder...153
Assembling The Steering Cylinder...155
STEERING CYLINDER (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...159
Removal And Installation...159
Parts Identification...161
Disassembly...162
Assembly...165
STEERING CYLINDER (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above)...171
Removing The Steering Cylinder...171
Installing The Steering Cylinder...173
Disassembling The Steering Cylinder...175
Assembling The Steering Cylinder...177
DRIVE BOX (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...181
Parts Identification...181
Disassembly...182
Inspection...187
Assembly...188
DRIVE BOX (For S/N 362812001 and Above, S/N 362912001 and Above)...195
Parts Identification...195
Disassembly...196
Assembly...200
SPECIAL TOOLS...203
MAIN RELIEF VALVE...205
Testing And Adjustment...205
QUICK TACH CYLINDER...209
Removal And Installation...209
Parts Identification...211
Disassembly...212
Assembly...215
FRAME LEVELING CYLINDER...217
Removal And Installation (For S/N 362811001 -362812000, S/N 362911001 - 362912000)...217
Removal And Installation (For S/N 362812001 andAbove, S/N 362912001 and Above)...218
Removal...219
Parts Identification...220
Disassembly...221
Assembly...226
STEERING MODE VALVE BLOCK...233
Removal And Installation...233
Parts Identification...235
Disassembly...236
Solenoid Testing...238
Assembly...238
BRAKE VALVE...241
Removal And Installation...241
Disassembly And Assembly...242
GEAR PUMP...245
Removal And Installation...245
Parts Identification...248
Disassembly And Assembly...249
FAN MOTOR...255
Removal And Installation...255
Parts Identification...259
Disassembly And Assembly (1 Speed Version)...260
Disassembly And Assembly (2 Speed Version)...263
HYDRAULIC RESERVOIR...267
Removal And Installation...267
STEERING VALVE...269
Removal And Installation...269
Parts Identification...270
Disassembly...271
Inspection...277
Assembly...277
HYDRAULIC CONTROL VALVE...285
Troubleshooting Chart (Controllers)...285
Telescoping Valve Section Troubleshooting...286
Auxiliary Valve Section Troubleshooting...290
Troubleshooting Chart (Control Valve)...294
Removal And Installation...295
Parts Identification...299
Disassembly And Assembly...300
End Housing Disassembly And Assembly...301
Lifting Valve Section Disassembly And Assembly...302
Tilting Valve Section Disassembly And Assembly...307
Telescoping Valve Section Disassembly And Assembly...312
Auxiliary/Frame Leveling Valve Section Disassembly And Assembly...324
Inlet-Outlet Valve Section Disassembly And Assembly...334
PORT RELIEF VALVES...339
Adjustment Procedure...339
FLOW CONTROL VALVE...341
Removal And Installation...341
JOYSTICK...343
Removal And Installation...343
Parts Identification...346
PARKING BRAKE...347
Parking Brake Valve Removal And Installation...347
Parking Brake Valve Disassembly And Assembly...348
PILOT PRESSURE LOCK OUT VALVE...349
Testing...349
Removal And Installation...350
Disassembly And Assembly...351
ACCUMULATOR...353
Removal And Installation...353
OPTIONAL...355
Removal And Installation...355
Disassembly And Assembly...356
HYDROSTATIC SYSTEM...361
HYDROSTATIC SYSTEM INFORMATION...363
Troubleshooting Chart...363
Replenishing Valve Function...364
OIL COOLER...365
Description...365
HYDROSTATIC DRIVE MOTOR...367
Removal And Installation...367
Parts Identification...368
Disassembly...371
Inspection...386
Assembly...388
HYDROSTATIC PUMP...405
Removal And Installation...405
Parts Identification...408
Disassembly...413
Inspection...425
Assembly...429
Charge Pressure Checking Procedure...444
Charge Pressure Adjusting Procedure...444
DRIVE SYSTEM...445
TROUBLESHOOTING...449
Chart...449
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...451
General Information...451
Planetary Carrier Parts Identification...451
Planetary Carrier Disassembly...452
Planetary Carrier Inspection...454
Wheel Hub Parts Identification...455
Wheel Hub Disassembly...456
Wheel Hub Inspection...459
Steering Knuckle Parts Identification...459
Steering Knuckle Disassembly...460
Axle Housing/Drive Axle Parts Identification...462
Axle Housing/Drive Axle Disassembly...463
Brake Group Parts Identification...468
Brake Group Disassembly...468
Brake Group Inspection...474
Differential Parts Identification...475
Differential Disassembly...475
Differential Inspection...478
Pinion Group Parts Identification...479
Pinion Group Disassembly...480
Pinion Group Inspection...482
Pinion Group Assembly...483
Differential Assembly...489
Brake Group Assembly...492
Axle Housing/Drive Axle Assembly...502
Steering Knuckle Assembly...507
Wheel Hub Assembly...510
Planetary Carrier Assembly...512
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...515
General Information...515
Planetary Carrier Parts Identification...515
Planetary Carrier Disassembly...516
Planetary Carrier Inspection...518
Wheel Hub Parts Identification...519
Wheel Hub Disassembly...520
Wheel Hub Inspection...523
Steering Knuckle Parts Identification...523
Steering Knuckle Disassembly...524
Axle Housing/Drive Axle Parts Identification...526
Axle Housing/Drive Axle Disassembly...527
Differential Parts Identification...530
Differential Parts Identification...530
Differential Disassembly...530
Differential Inspection...537
Pinion Group Parts Identification...538
Pinion Group Disassembly...539
Pinion Group Inspection...542
Pinion Group Assembly...543
Differential Assembly...549
Axle Housing/Drive Axle Assembly...560
Steering Knuckle Assembly...563
Wheel Hub Assembly...566
Planetary Carrier Assembly...568
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above)...571
General Information...571
Planetary Carrier Parts Identification...571
Planetary Carrier Disassembly...572
Steering Knuckle and Drive Axle Parts Identification...577
Steering Knuckle Disassembly...578
Drive Axle Disassembly...580
Brake system Identification...582
Brake System Disassembly...583
Differential Parts Identification...587
Differential Disassembly...588
Bevel pinion Parts Identification...593
Bevel Pinion Disassembly...594
Bevel Pinion Assembly...597
Differential Assembly...606
Brake System Assembly...611
Drive Axle Assembly...618
Steering Knuckle Assembly...620
Planetary carrier Assembly...623
SPECIAL TOOLS...628
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above)...629
General Information...629
Planetary Carrier Parts Identification...629
Planetary Carrier Disassembly...630
Steering Knuckle and Drive Axle Parts Identification...635
Steering Knuckle Disassembly...636
Differential and Bevel Pinion Parts Identification...638
Differential Disassembly...639
Bevel pinion Disassembly...643
Bevel pinion Assembly...646
Differential Assembly...654
Steering Knuckle Assembly...659
Planetary Carrier Assembly...662
Special tools...666
FRONT AXLE WITHOUT FRAME LEVELING (For S/N 362811001 - 362812000)...667
Removal...667
Installation...673
FRONT AXLE WITH FRAME LEVELING (For S/N 362911001 - 362912000)...679
Removal...679
Installation...684
AXLE TOE-IN (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...707
Adjustment...707
AXLE TOE-IN (For S/N 362812001 and Above, S/N 362912001 and Above)...709
Adjustment...709
PARKING BRAKE (For S/N 362811001 - 362812000, S/ N 362911001 - 362912000)...711
Preparing For Towing...711
Disengaging The Hydrostatic Transmission ...711
Releasing The Parking Brake...712
Towing The Telescopic Handler...712
PARKING BRAKE (For S/N 362812001 and Above, S/...713
Preparing For Towing...713
Disengaging The Hydrostatic Transmission...713
Releasing The Parking Brake...714
Towing The Telescopic Handler...714
STEERING ANGLE ADJUSTMENT (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...715
Adjustment...715
STEERING ANGLE ADJUSTMENT (For S/N 362812001and Above, S/N 362912001 and Above)...717
Adjustment...717
DRIVESHAFT...719
Removal And Installation...719
SERVICE BRAKE (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...721
Description...721
Bleeding The Brake Circut...721
SERVICE BRAKE (For S/N 362812001 and Above, S/N 362912001 and Above)...723
Description...723
Bleeding The Brake Circuit...723
REAR AXLE (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...725
Removal...725
Installation...728
REAR AXLE (For S/N 362812001 and Above, S/N 362912001 and Above)...733
Removal...733
Installation...736
MAIN FRAME...741
OPERATOR CAB...743
Removal And Installation...743
OPERATOR SEAT...751
BOOM ASSEMBLY...753
Removal And Installation...753
INNER BOOM...757
Removal...757
Installation...759
WEAR PADS (FRONT)...761
Removal And Installation...761
WEAR PADS (REAR)...763
Removal...763
Installation...763
ENGINE COVER...765
Gas Cylinder Removal And Installation...765
Removal And Installation...765
AIR INTAKE COWLING...767
Removal And Installation...767
FUEL TANK...769
Removal And Installation...769
QUICK TACH...773
Removal And Installation...773
REAR WEIGHTS...775
Removal And Installation...775
FENDER...777
Removal And Installation...777
PIVOT LINK...779
Removal And Installation...779
DASH COVER/STEERING COLUMN COVER...783
Removal And Installation...783
JOYSTICK PANEL...787
Removal And Installation...787
ELECTRICAL SYSTEM AND ANALYSIS...789
ELECTRICAL SYSTEM INFORMATION...791
Troubleshooting Chart...791
Description...792
Fuses, Diodes & Relays...792
BATTERY...797
Removal And Installation...797
Servicing...798
Using A Booster Battery (Jump Starting)...799
ALTERNATOR...801
Removal And Installation...801
Adjusting The Alternator Belt...802
STARTER...803
Removal And Installation...803
Parts Identification...804
Assembly/Disassembly...805
LIGHTS...807
Rear Light Removal And Installation...807
Front Light Removal And Installation...808
TRAVEL/SIGNAL LEVER...809
Removal And Installation...809
INSTRUMENT PANEL...811
Removal And Installation...811
SWITCH PANEL...813
Parts Description...813
BRAKE LIGHT SWITCH...815
Removal And Installation...815
Adjustment...815
FRONT WIPER MOTOR...817
Removal And Installation...817
TOP WIPER MOTOR...821
Removal And Installation...821
REAR WIPER MOTOR...823
Removal And Installation...823
PEDAL ASSEMBLY...825
Removal And Installation...825
Disassembly And Assembly...826
INCHING SWITCH...831
Removal And Installation...831
Adjustment...831
SERVICE SOFTWARE...833
Connecting The Laptop Computer...833
Entering The Service Software...834
Monitor Screen...835
Warnings Screen...836
Calibrate Inch Pedal...837
FRAME LEVEL SPEED SWITCH...839
Description...839
Removal...839
Installation...840
Disassembly And Assembly...841
LONGITUDINAL STABILITY INDICATOR CALIBRATION...843
Fitting The Sensor...843
Calibration Procedure...843
ENGINE SERVICE...845
TROUBLESHOOTING...849
Chart...849
ENGINE SPEED CONTROL...851
Removal And Installation...851
MUFFLER...853
Removal And Installation...853
AIR CLEANER...855
Housing Removal And Installation...855
OIL COOLER/RADIATOR...857
Removal And Installation...857
Disassembly And Assembly...859
ENGINE AND ENGINE MOUNTS...861
Removal And Installation...861
ENGINE COMPONENTS AND TESTING...865
Fuel Injection Pump Removal...865
Fuel Injection Pump Installation...868
Fuel Injectors Removal And Installation...871
Fuel Lift Pump Removal And Installation...874
Compression Testing...875
Glow Plugs Checking...876
Glow Plugs Removal And Installation...876
ENGINE TIMING...879
Procedure...879
ENGINE/HYDROSTAT ASSEMBLY...881
Removal And Installation...881
FLYWHEEL AND HOUSING...893
Removal And Installation...893
RECONDITIONING THE ENGINE...897
Turbo Charger Troubleshooting...897
Turbo Charger Description...898
Turbo Charger Removal And Installation...898
Exhaust Manifold Removal And Installation...900
Fuel Injector Cover Removal And Installation...900
Rocker Cover Removal And Installation...901
Cylinder Head Removal...902
Cylinder Head Inspection...904
Cylinder Head Installation...904
Rocker Shaft Disassembly And Assembly...907
Valve Removal...907
Valve Springs Checking...908
Valve Depth Checking...908
Valve Guides Checking...909
Valve Guide Removal...910
Valve Guide Installation...910
Valves Checking...911
Cutting A Valve Seat...911
Valve Seat Assembly...912
Changing The Valve Springs (With Cylinder Head Installed)...913
Valve Clearance Adjustment...914
Timing Case And Drive Assembly Description...915
Timing Cover Removal...915
Timing Cover Installation...915
Crankshaft Pulley Removal And Installation...915
Front Oil Seal Removal And Installation...915
Timing Case And Gear Removal...916
Timing Case And Gear Installation...917
Camshaft And Tappets Removal...919
Camshaft And Tappets Installation...920
Pistons And Connecting Rods Description...922
Pistons And Connecting Rods Removal...922
Pistons And Connecting Rods Disassembly...924
Piston Ring End Gap...924
Piston Ring Groove Clearance...925
Connecting Rod Inspection...926
Connecting Rod Bushing Replacement...926
Piston And Connecting Rod Assembly...926
Checking Piston Height...928
Crankshaft And Bearings Removal...929
Inspection Of Crankshaft And Bearings...931
Crankshaft And Bearings Installation...931
Rear Oil Seal Removal...933
Rear Oil Seal Installation...933
Checking Crankshaft End Play...934
Cooling System Description...935
Thermostat Removal And Installation...936
Thermostat Testing...936
Water Pump Removal...937
Water Pump Installation...937
Engine Lubrication System Description...938
Oil Filter Adapter Removal And Installation...939
Oil Pan Removal And Installation...939
Oil Screen And Pick-up Tube...940
Oil Pump Removal...940
Oil Pump Installation...941
Oil Pump Disassembly And Assembly...942
Oil Pressure Relief Valve Disassembly And Assembly...942
Engine Block Description...943
Engine Block Disassembly And Assembly...943
Piston Cooling Jet Removal...944
Piston Cooling Jet Installation...944
Piston Cooling Jet Alignment...944
Inspection...944
Cylinder Liner Inspection...945
Cylinder Liner Removal...946
Cylinder Liner Installation...947
HEATING, VENTILATION, AIR CONDITIONING...949
AIR CONDITIONING SYSTEM FLOW...952
Principals...952
Chart...953
COMPONENTS...955
Identificaton...955
SAFETY...957
Safety Equipment...957
REGULAR MAINTENANCE...959
Filter Element Removal And Installation...959
Compressor Drive Belt Inspection...960
Cleaning The Condenser...960
BASIC TROUBLESHOOTING...961
Poor A/C Performance...961
Compressor Drive Belt Inspection...961
Checking The Electrical System...962
GENERAL AIR CONDITIONING SERVICE GUIDELINES...967
Compressor Oil...967
Compressor Oil Check...967
SYSTEM TROUBLESHOOTING CHART...969
TEMPERATURE/PRESSURE...973
Chart...973
AIR CONDITIONING SERVICE...975
Chart...975
SYSTEM CHARGING AND RECLAMATION...977
Reclamation Procedure...977
Charging Procedure With A Manifold Gauge Set...980
Charging Procedure...981
COMPRESSOR...983
Removal And Installation...983
Compressor Clutch Disassembly And Assembly...984
CONDENSER...989
Removal And Installation...989
RECEIVER/DRIER...991
Removal And Installation...991
PRESSURE SWITCH...993
Removal And Installation...993
EVAPORATOR/BLOWER UNIT...995
Removal And Installation...995
EXPANSION VALVE...997
Removal And Installation...997
HEATER ASSEMBLY...999
Removal And Installation...999
Fan Removal And Installation...1000
Core Removal And Installation...1000
SPECIFICATIONS...1003
Telescopic Handler SPECIFICATIONS...1005
Dimensional Specifications...1005
Performance Specification...1006
Engine...1006
Controls...1006
Drive System...1006
Tires...1007
Capacities...1007
Hydraulic System...1007
Electrical System...1007
Instrument Panel...1007
ENGINE SPECIFICATIONS...1009
General...1009
Cylinder Head...1009
Valve Guides...1009
Exhaust Valves...1010
Intake Valves...1010
Valve Springs...1010
Rocker Shaft, Rockers And Bushings...1011
Pistons And Piston Rings...1011
Connecting Rods And Bearings...1012
Crankshaft...1012
Crankshaft Re-Grind Data...1013
Main Bearings...1014
Thrust Washers...1014
Camshaft And Thrust Washer...1014
Cylinder Block...1014
Cylinder Liners...1015
Fuel Injection Pump...1015
Fuel Injectors...1015
Fuel Lift Pump...1015
Timing Case And Timing Gears...1016
Oil Pump, Gear And Relief Valve...1017
Turbocharger...1017
Flywheel...1017
Water Pump And Thermostat...1018
Engine Torque Component...1019
MACHINE TORQUE SPECIFICATIONS...1021
Axle...1021
Boom...1021
Drive Box...1021
Drive Motor...1021
Engine...1022
Hydraulic Pump...1022
TORQUE SPECIFICATIONS FOR BOLTS...1023
Torque for General SAE Bolts...1023
Torque For General Metric Bolts...1024
HYDRAULIC CONNECTION SPECIFICATIONS...1025
O-ring Face Seal Connection...1025
Straight Thread O-ring Fitting...1025
Tubelines And Hoses...1025
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...1031
Specifications...1031
CONVERSIONS...1033
Decimal And Millimeter Equivalents...1033
U.S. To Metric Conversion...1034
SERVICE MANUAL REVISION...1035
Revision No: T3571, T3571L - 1...1035
4852150 (7-06) - T3571, T3571L Service Manual...1037
T3571...1037
S/N 362811001 & above...1037
T3571L...1037
S/N 362911001 & above...1037
MAINTENANCE SAFETY...1039
ALPHABETICAL INDEX...1041
ALPHABETICAL INDEX (CONT’D)...1042
Contents...1043
FOReWORD II...1043
SAFETY INSTRUCTIONS V...1043
Serial Number LocationS VII...1043
Delivery Report VII...1043
Identification of the telescopic handler VIII...1043
SAFETY AND MAINTENANCE 10-01...1043
HYDRAULIC SYSTEM 20-01...1043
HYDROSTATIC SYSTEM 30-01...1043
DRIVE SYSTEM 40-01...1043
MAIN FRAME 50-01...1043
ELECTRICAL SYSTEM AND ANALYSIS 60-01...1043
ENGINE SERVICE 70-01...1043
HEATING, VENTILATION, AIR CONDITIONING 80-01...1043
SPECIFICATIONS SPEC-01...1043
FOReWORD...1044
This manual is for the Bobcat Telescopic Handler mechanic. It provides necessary servicing and adjustment procedures for the Bob...1044
A general inspection of the following items must be made after the Telescopic Handler has had service or repair:...1044
SAFETY INSTRUCTIONS...1047
Before Operation...1047
SAFETY INSTRUCTIONS (CONT’D)...1048
Safe Operation Is The Operator’s Responsibility...1048
Safe Operation Needs A Qualified Operator...1048
A Qualified Operator Must Do The Following:...1048
Serial Number LocationS...1049
Telescopic Handler Serial Number...1049
Figure 1...1049
Engine Serial Number...1049
Figure 2...1049
Other Serial Numbers...1049
Delivery Report...1049
Figure 3...1049
Identification of the telescopic handler...1050
Figure 4...1050
SAFETY AND MAINTENANCE...1051
AIR CLEANER SERVICE 10-60-1...1051
Replacing Filter Element 10-60-1...1051
OPTIONAL APPROVED BOOM STOP 10-150-1...1051
Installing The Approved Boom Stop 10-150-1...1051
Removing The Approved Boom Stop 10-150-1...1051
AXLES (FRONT AND REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) 10-110-1...1051
Checking Oil Level (Front Differential) 10-110-2...1051
Checking Oil Level (Planetary Carrier) 10-110-1...1051
Checking Oil Level (Rear Differential) 10-110-2...1051
Draining Oil (Front Differential) 10-110-2...1051
Draining Oil (Planetary Carrier) 10-110-1...1051
Draining Oil (Rear Differential) 10-110-2...1051
AXLES (FRONT AND REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) 10-111-1...1051
Checking Oil Level (Front Differential) 10-111-2...1051
Checking Oil Level (Planetary Carrier) 10-111-1...1051
Checking Oil Level (Rear Differential) 10-111-2...1051
Draining Oil (Front Differential) 10-111-3...1051
Draining Oil (Planetary Carrier) 10-111-1...1051
Draining Oil (Rear Differential) 10-111-2...1051
ENGINE COOLING SYSTEM 10-70-1...1051
Checking The Coolant Level 10-70-1...1051
Cleaning The Cooling System 10-70-1...1051
Replacing The Coolant 10-70-2...1051
ENGINE COVER 10-160-1...1051
Opening And Closing The Engine Cover 10-160-1...1051
ENGINE LUBRICATION SYSTEM 10-90-1...1051
Checking Engine Oil 10-90-1...1051
Oil Chart 10-90-1...1051
Replacing Oil And Filter 10-90-2...1051
FUEL SYSTEM 10-80-1...1051
Filling The Fuel Tank 10-80-1...1051
Fuel Filter 10-80-1...1051
Fuel Specifications 10-80-1...1051
Continued On Next Page...1051
SAFETY AND MAINTENANCE (Cont’d)...1052
HYDRAULIC/HYDROSTATIC SYSTEM 10-100-1...1052
Checking And Adding Fluid 10-100-1...1052
Replacing Hydraulic Fluid 10-100-3...1052
LIFTING AND BLOCKING THE Telescopic Handler 10-10-1...1052
Procedure 10-10-1...1052
LUBRICATION (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) 10-120-1...1052
Procedure 10-120-1...1052
LUBRICATION (For S/N 362812001 and Above, S/N 362912001 and Above) 10-121-1...1052
Procedure 10-121-1...1052
OPERATOR CAB 10-20-1...1052
Cab Door 10-20-2...1052
Cab Door Window 10-20-2...1052
Emergency Exit 10-20-1...1052
SERVICE SCHEDULE 10-50-1...1052
TIRE MAINTENANCE 10-130-1...1052
Tire Mounting 10-130-1...1052
Tire Rotation 10-130-1...1052
Wheel Nuts 10-130-1...1052
TOWING THE Telescopic Handler 10-40-1...1052
Preparing for towing 10-40-1...1052
Disengaging the hydrostatic transmission 10-40-1...1052
Releasing the handbrake (For S/N 362811001 - 362812000, S/N 362911001 - 368012000): 10-40-2...1052
Releasing the handbrake (For S/N 362812001 and Above, S/N 362912001 and Above): 10-40-2...1052
Towing the Telescopic Handler 10-40-3...1052
TRANSPORTING THE Telescopic Handler 10-30-1...1052
Procedure 10-30-1...1052
LIFTING AND BLOCKING THE Telescopic Handler...1053
Figure 10-10-1...1053
Figure 10-10-2...1053
OPERATOR CAB...1055
Figure 10-20-1...1055
Figure 10-20-2...1055
OPERATOR CAB (CONT’D)...1056
Figure 10-20-3...1056
Figure 10-20-4...1056
Figure 10-20-5...1056
Figure 10-20-6...1056
TRANSPORTING THE Telescopic Handler...1057
Figure 10-30-1...1057
TOWING THE Telescopic Handler...1059
Preparing for towing...1059
The Telescopic Handler can be towed a short distance such as removing it from mud or loading onto a transport vehicle...1059
The machine must be prepared before towing...1059
Disengaging the hydrostatic transmission...1059
It is impossible for oil to circulate in a hydrostatic transmission in a closed circuit when the machine is not running, this operation involves making oil circulation possible:...1059
Figure 10-40-2...1059
If the optional tow valve is installed, simply raise the engine cover and turn the valve counterclockwise 90 (Item 1) [Figure 10-40-2] to TOWING POSITION...1059
Follow the below procedure if the optional tow valve is not installed:...1059
Figure 10-40-3...1059
TOWING THE Telescopic Handler (CONT’d)...1060
Releasing the handbrake (For S/N 362811001 - 362812000, S/N 362911001 - 368012000):...1060
As the machine’s handbrake is tightened by lack of pressure, this operation involves releasing the brake mechanically:...1060
Figure 10-40-4...1060
Figure 10-40-5...1060
The brakes are now released for towing the vehicle...1060
Releasing the handbrake (For S/N 362812001 and Above, S/N 362912001 and Above):...1060
As the machine’s brakes are tightened by lack of hydraulic pressure (= handbraked position), this operation involves releasing the brakes mechanically. Only the front axle has brakes...1060
The following procedure describes how to untighten the brakes...1060
Figure 10-40-6...1060
Figure 10-40-7...1060
The brakes are now released for towing the vehicle...1060
TOWING THE Telescopic Handler (CONT’d)...1061
Towing the Telescopic Handler...1061
Tow the Telescopic Handler at slow speed...1061
After towing:...1061
SERVICE SCHEDULE...1063
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat Telescopic Handler...1063
AIR CLEANER SERVICE...1065
Figure 10-60-1...1065
Figure 10-60-2...1065
Figure 10-60-3...1065
AIR CLEANER SERVICE (CONT’D)...1066
Figure 10-60-4...1066
ENGINE COOLING SYSTEM...1067
Figure 10-70-1...1067
Figure 10-70-2...1067
Figure 10-70-3...1067
ENGINE COOLING SYSTEM (CONT’D)...1068
Figure 10-70-4...1068
Figure 10-70-5...1068
FUEL SYSTEM...1069
Figure 10-80-1...1069
Figure 10-80-2...1069
ENGINE LUBRICATION SYSTEM...1071
Figure 10-90-1...1071
Oil Chart...1071
Figure 10-90-2...1071
ENGINE LUBRICATION SYSTEM (CONT’D)...1072
Figure 10-90-3...1072
Figure 10-90-4...1072
Figure 10-90-5...1072
HYDRAULIC/HYDROSTATIC SYSTEM...1073
Figure 10-100-1...1073
Figure 10-100-2...1073
Figure 10-100-3...1073
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)...1074
Figure 10-100-4...1074
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)...1075
Figure 10-100-5...1075
Figure 10-100-6...1075
AXLES (FRONT AND REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...1077
Figure 10-110-1...1077
Figure 10-110-2...1077
AXLES (FRONT AND REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1078
Figure 10-110-3...1078
Figure 10-110-4...1078
Figure 10-110-5...1078
Figure 10-110-6...1078
AXLES (FRONT AND REAR) (For S/N 362812001 and Above, S/N 362912001 and Above)...1079
Figure 10-10-111-2...1079
AXLES (FRONT AND REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (Cont'd)...1080
Figure 10-10-111-3...1080
Figure 10-10-111-4...1080
Figure 10-10-111-5...1080
Figure 10-10-111-6...1080
Figure 10-10-111-7...1081
Figure 10-10-111-8...1081
Figure 10-10-111-9...1081
Figure 10-10-111-10...1081
LUBRICATION (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...1083
Figure 10-120-1...1083
1. Axle Pivots - Top and bottom (Item 1) [Figure 10-120- 1] all four wheels...1083
Figure 10-120-2...1083
2. Universal Joints - Front and Rear (Item 1) [Figure 10- 120-2]...1083
Figure 10-120-3...1083
3. Axle Oscillation - Rear Axle (Item 1) [Figure 10-120- 3]...1083
Figure 10-120-4...1083
4. Attachment Frame Pivot (Item 1) [Figure 10-120-4]...1083
LUBRICATION (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1084
Figure 10-120-5...1084
5. Lower Pivot Link (Item 1) [Figure 10-120-5]...1084
Figure 10-120-6...1084
6. Remove the two cover bolts (Item 1) and cover (Item 2) [Figure 10-120-6]...1084
Figure 10-120-7...1084
7. Main Pivot Link (Item 1) [Figure 10-120-7]...1084
Figure 10-120-8...1084
8. Extension Cylinder Rod End (Item 1) [Figure 10-120- 8]...1084
LUBRICATION (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1085
Figure 10-120-9...1085
9. Lift Cylinder Rod End (Item 1) [Figure 10-120-9]...1085
Figure 10-120-10...1085
10. Lift Cylinder Base End (Item 1) [Figure 10-120-10]...1085
Figure 10-120-11...1085
11. Base End Slave Cylinder (Item 1) [Figure 10-120-11]...1085
Figure 10-120-12...1085
12. Slave Cylinder Pivot Bracket (Item 1) [Figure 10-120- 12]...1085
LUBRICATION (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1086
Figure 10-120-13...1086
13. Boom Pivot (Item 1) [Figure 10-120-13] (Four Places)...1086
Figure 10-120-14...1086
14. Boom Slide [Figure 10-120-14] (Four Places)...1086
Figure 10-120-15...1086
15. Axle Oscillation - Front Axle (Item 1) [Figure 10-120- 15] (With Frame Leveling Only)...1086
Figure 10-120-16...1086
16. Axle Oscillation - Front Axle (Item 1) [Figure 10-120- 16] (With Frame Leveling Only)...1086
LUBRICATION (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1087
Figure 10-120-17...1087
17. Cab door hinges (upper) (Item 1) [Figure 10-120-17]...1087
Figure 10-120-18...1087
18. Cab door hinges (lower) (Item 1) [Figure 10-120-18]...1087
LUBRICATION (For S/N 362812001 and Above, S/N 362912001 and Above)...1089
1. Axle Pivots - Top and bottom (Item 1) [Figure 10-121- 1] all four wheels...1089
Figure 10-121-2...1089
2. Universal Joints - Front and Rear (Item 1) [Figure 10- 121-2] (earlier models only)...1089
Figure 10-121-3...1089
3. Axle Oscillation - Rear Axle (Item 1) [Figure 10-121- 3]...1089
Figure 10-121-4...1089
4. Attachment Frame Pivot (Item 1) [Figure 10-121-4]...1089
LUBRICATION (Cont'd) (For S/N 362812001 and Above, S/N 362912001 and Above)...1090
Figure 10-121-5...1090
5. Lower Pivot Link (Item 1) [Figure 10-121-5]...1090
Figure 10-121-6...1090
6. Remove the two cover bolts (Item 1) and cover (item 2) [Figure 10-121-6]...1090
Figure 10-121-7...1090
7. Main Pivot Link (Item 1) [Figure 10-121-7]...1090
Figure 10-121-8...1090
8. Extension Cylinder Rod End (Item 1) [Figure 10-121- 8]...1090
LUBRICATION (Cont'd) (For S/N 362812001 and Above, S/N 362912001 and Above)...1091
Figure 10-121-9...1091
9. Lift Cylinder Rod End (Item 1) [Figure 10-121-9]...1091
Figure 10-121-10...1091
10. Lift Cylinder Base End (Item 1) [Figure 10-121-10]...1091
Figure 10-121-11...1091
11. Base End Slave Cylinder (Item 1) [Figure 10-121-11]...1091
Figure 10-120-1...1091
12. Slave Cylinder Pivot Bracket (Item 1) [Figure 10-120- 1]...1091
LUBRICATION (Cont'd) (For S/N 362812001 and Above, S/N 362912001 and Above)...1092
Figure 10-121-1...1092
13. Boom Pivot (Item 1) [Figure 10-121-1] (Four Places)...1092
Figure 10-121-2...1092
14. Boom Slide [Figure 10-121-2] (Four Places)...1092
Figure 10-121-3...1092
15. Axle Oscillation - Front Axle (Item 1) [Figure 10-121- 3] (With Frame Leveling Only)...1092
Figure 10-121-4...1092
16. Axle Oscillation - Front Axle (Item 1) [Figure 10-121- 4] (With Frame Leveling Only)...1092
LUBRICATION (CONT’D) (For S/N 362812001 and Above, S/N 362912001 and Above)...1093
Figure 10-121-5...1093
17. Cab Door Hinges (item 1) [Figure 10-121-5] (Upper)...1093
Figure 10-121-6...1093
18. Cab Door Hinges (item 1) [Figure 10-121-6] (Lower)...1093
Figure 10-121-7...1093
19. Universal joint (Item 1) [Figure 10-121-7]...1093
TIRE MAINTENANCE...1095
Figure 10-130-2...1095
SPARK ARRESTOR MUFFLER...1097
Figure 10-140-3...1097
OPTIONAL APPROVED BOOM STOP...1099
Figure 10-150-1...1099
Figure 10-150-2...1099
ENGINE COVER...1101
AVOID INJURY OR DEATH...1101
Never service or adjust the machine when the engine is running unless instructed to do so in the manual...1101
Figure 10-160-1...1101
HYDRAULIC SYSTEM...1103
ACCUMULATOR 20-210-1...1103
Removal And Installation 20-210-1...1103
BRAKE VALVE 20-120-1...1103
Disassembly And Assembly 20-120-2...1103
Removal And Installation 20-120-1...1103
BUCKET POSITIONING CYLINDER 20-30-1...1103
Assembly 20-30-9...1103
Disassembly 20-30-5...1103
Parts Identification 20-30-4...1103
Removal And Installation 20-30-1...1103
DRIVE BOX (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) 20-70-1...1103
Assembly 20-70-8...1103
Disassembly 20-70-2...1103
Inspection 20-70-77...1103
Parts Identification 20-70-1...1103
DRIVE BOX (For S/N 362812001 and Above, S/N 362912001 and Above) 20-71-1...1103
Assembly 20-71-6...1103
Disassembly 20-71-2...1103
Parts Identification 20-71-1...1103
EXTENSION CYLINDER 20-40-1...1103
Assembly 20-40-18...1103
Cylinder Group Removal And Installation 20-40-1...1103
Disassembly 20-40-14...1103
Extension Cylinder Removal And Installation 20-40-5...1103
Parts Identification 20-40-13...1103
Tubeline Tray Assembly 20-40-9...1103
Tubeline Tray Disassembly 20-40-7...1103
Upper Tubeline Installation 20-40-3...1103
Upper Tubeline Removal 20-40-3...1103
FAN MOTOR 20-140-1...1103
Disassembly And Assembly (1 speed version) 20-140-6...1103
Parts Identification 20-140-5...1103
Removal And Installation 20-140-1...1103
FLOW CONTROL VALVE 20-172-1...1103
Removal And Installation 20-172-1...1103
HYDRAULIC SYSTEM (COnt’d)...1104
FRAME LEVELING CYLINDER 20-100-1...1104
Assembly 20-100-10...1104
Disassembly 20-100-5...1104
Parts Identification 20-100-4...1104
Removal And Installation (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) 20-100-1...1104
Removal And Installation (For S/N 362812001 and Above, S/N 362912001 and Above) 20-100-2...1104
GEAR PUMP 20-130-1...1104
Disassembly And Assembly 20-130-5...1104
Parts Identification 20-130-4...1104
Removal And Installation 20-130-1...1104
HYDRAULIC CONTROL VALVE (CONT’D) 20-170-11...1104
Auxiliary/Frame Leveling Valve Section Disassembly And Assembly 20-170-40...1104
Disassembly And Assembly 20-170-16...1104
End Housing Disassembly And Assembly 20-170-17...1104
Inlet-Outlet Valve Section Disassembly And Assembly 20-170-50...1104
Lifting Valve Section Disassembly And Assembly 20-170-18...1104
Parts Identification 20-170-15...1104
Removal And Installation 20-170-11...1104
Telescoping Valve Section Disassembly And Assembly 20-170-28...1104
Tilting Valve Section Disassembly And Assembly 20-170-23...1104
HYDRAULIC RESERVOIR 20-150-1...1104
Removal And Installation 20-150-1...1104
HYDRAULIC SYSTEM INFORMATION 20-10-1...1104
Tightening Procedures 20-10-5...1104
Troubleshooting Chart 20-10-4...1104
JOYSTICK 20-180-1...1104
Removal And Installation 20-180-1...1104
LIFT CYLINDER 20-20-1...1104
Assembly 20-20-11...1104
Disassembly 20-20-6...1104
Parts Identification 20-20-5...1104
Removal And Installation 20-20-1...1104
MAIN RELIEF VALVE 20-80-1...1104
MAIN RELIEF VALVE (CONT’D) 20-80-3...1104
Testing And Adjustment 20-80-1...1104
hydraulic system (cont’d)...1105
PARKING BRAKE 20-190-1...1105
Parking Brake Valve Disassembly And Assembly 20-190-2...1105
Parking Brake Valve Removal And Installation 20-190-1...1105
PORT RELIEF VALVES 20-171-1...1105
Adjustment Procedure 20-171-1...1105
PILOT PRESSURE LOCK OUT VALVE 20-200-1...1105
Disassembly And Assembly 20-200-3...1105
Removal And Installation 20-200-2...1105
Testing 20-200-1...1105
QUICK TACH CYLINDER 20-90-1...1105
Assembly 20-90-7...1105
Disassembly 20-90-4...1105
Parts Identification 20-90-3...1105
Removal And Installation 20-90-1...1105
STEERING CYLINDER (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) 20-60-1...1105
Assembly 20-60-7...1105
Disassembly 20-60-4...1105
Parts Identification 20-60-3...1105
Removal And Installation 20-60-1...1105
STEERING CYLINDER (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) 20-61-1...1105
Assembling the Steering Cylinder 20-61-7...1105
Disassembling the Steering Cylinder 20-61-5...1105
Removing the Steering Cylinder 20-61-1...1105
Installing the Steering Cylinder 20-61-3...1105
STEERING CYLINDER (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) 20-62-1...1105
Assembly 20-62-7...1105
Disassembly 20-62-4...1105
Parts Identification 20-62-3...1105
Removal And Installation 20-62-1...1105
hydraulic system (cont’d)...1106
STEERING CYLINDER (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) 20-63-1...1106
Assembling the Steering Cylinder 20-63-7...1106
Disassembling the Steering Cylinder 20-63-5...1106
Removing the Steering Cylinder 20-63-1...1106
Installing the Steering Cylinder 20-63-3...1106
STEERING MODE VALVE BLOCK 20-110-1...1106
Assembly 20-110-6...1106
Disassembly 20-110-4...1106
Parts Identification 20-110-3...1106
Removal And Installation 20-110-1...1106
Solenoid Testing 20-110-6...1106
STEERING VALVE 20-160-1...1106
Assembly 20-160-9...1106
Disassembly 20-160-3...1106
Inspection 20-160-9...1106
Parts Identification 20-160-2...1106
Removal And Installation 20-160-1...1106
TILT CYLINDER 20-50-1...1106
Assembly 20-50-7...1106
Disassembly 20-50-3...1106
Parts Identification 20-50-2...1106
Removal And Installation 20-50-1...1106
Optional TOW VALVE 20-220-1...1106
Disassembly And Assembly 20-220-2...1106
Removal And Installation 20-220-1...1106
HYDRAULIC SYSTEM INFORMATION...1107
HYDRAULIC SYSTEM INFORMATION (CONT’D)...1108
HYDRAULIC SYSTEM INFORMATION (CONT’D)...1109
HYDRAULIC SYSTEM INFORMATION (CONT’D)...1110
HYDRAULIC SYSTEM INFORMATION (CONT’D)...1111
LIFT CYLINDER...1113
Figure 20-20-1...1113
Figure 20-20-2...1113
Figure 20-20-3...1113
Figure 20-20-4...1113
LIFT CYLINDER (Cont'd)...1114
Figure 20-20-5...1114
Figure 20-20-6...1114
1. Rotate the battery disconnect switch (Item 1) [Figure 20-20-6] to the right to disconnect the power supply from the battery...1114
Figure 20-20-7...1114
2. The side window (Item 1) and frame opening (Item 2) [Figure 20-20-7] must be protected from sparks...1114
Figure 20-20-8...1114
3. The cylinder rod must be wrapped with a damp welding blanket (Item 1) [Figure 20-20-8] to prevent damage...1114
LIFT CYLINDER (Cont'd)...1115
Figure 20-20-9...1115
Figure 20-20-10...1115
Figure 20-20-11...1115
Figure 20-20-12...1115
LIFT CYLINDER (Cont'd)...1116
Figure 20-20-13...1116
Figure 20-20-14...1116
Figure 20-20-15...1116
LIFT CYLINDER (Cont'd)...1117
Parts Identification...1117
LIFT CYLINDER (Cont'd)...1118
Figure 20-20-16...1118
Figure 20-20-17...1118
Figure 20-20-18...1118
Figure 20-20-19...1118
LIFT CYLINDER (Cont'd)...1119
Figure 20-20-20...1119
Figure 20-20-21...1119
Figure 20-20-22...1119
Figure 20-20-23...1119
LIFT CYLINDER (Cont'd)...1120
Figure 20-20-24...1120
Figure 20-20-25...1120
Figure 20-20-26...1120
Figure 20-20-27...1120
LIFT CYLINDER (Cont'd)...1121
Figure 20-20-28...1121
Figure 20-20-29...1121
Figure 20-20-30...1121
Figure 20-20-31...1121
LIFT CYLINDER (Cont'd)...1122
Figure 20-20-32...1122
Figure 20-20-33...1122
LIFT CYLINDER (Cont'd)...1123
Figure 20-20-34...1123
Figure 20-20-35...1123
Figure 20-20-36...1123
Figure 20-20-37...1123
LIFT CYLINDER (Cont'd)...1124
Figure 20-20-38...1124
Figure 20-20-39...1124
Figure 20-20-40...1124
Figure 20-20-41...1124
LIFT CYLINDER (Cont'd)...1125
Figure 20-20-42...1125
Figure 20-20-43...1125
Figure 20-20-44...1125
Figure 20-20-45...1125
LIFT CYLINDER (Cont'd)...1126
Figure 20-20-46...1126
Figure 20-20-47...1126
Figure 20-20-48...1126
Figure 20-20-49...1126
LIFT CYLINDER (Cont'd)...1127
Figure 20-20-50...1127
BUCKET POSITIONING CYLINDER...1129
Figure 20-30-1...1129
Figure 20-30-2...1129
Figure 20-30-3...1129
Figure 20-30-4...1129
BUCKET POSITIONING CYLINDER (Cont'd)...1130
Figure 20-30-5...1130
Figure 20-30-6...1130
Figure 20-30-7...1130
Figure 20-30-8...1130
BUCKET POSITIONING CYLINDER (Cont'd)...1131
Figure 20-30-9...1131
Figure 20-30-10...1131
BUCKET POSITIONING CYLINDER (CONT’D)...1132
BUCKET POSITIONING CYLINDER (Cont'd)...1133
Figure 20-30-11...1133
Figure 20-30-12...1133
Figure 20-30-13...1133
Figure 20-30-14...1133
BUCKET POSITIONING CYLINDER (Cont'd)...1134
Figure 20-30-15...1134
Figure 20-30-16...1134
Figure 20-30-17...1134
Figure 20-30-18...1134
BUCKET POSITIONING CYLINDER (Cont'd)...1135
Figure 20-30-19...1135
Figure 20-30-20...1135
Figure 20-30-21...1135
Figure 20-30-22...1135
BUCKET POSITIONING CYLINDER (Cont'd)...1136
Figure 20-30-23...1136
Figure 20-30-24...1136
Figure 20-30-25...1136
BUCKET POSITIONING CYLINDER (Cont'd)...1137
Figure 20-30-26...1137
Figure 20-30-27...1137
Figure 20-30-28...1137
Figure 20-30-29...1137
BUCKET POSITIONING CYLINDER (Cont'd)...1138
Figure 20-30-30...1138
Figure 20-30-31...1138
Figure 20-30-32...1138
Figure 20-30-33...1138
BUCKET POSITIONING CYLINDER (Cont'd)...1139
Figure 20-30-34...1139
Figure 20-30-35...1139
Figure 20-30-36...1139
Figure 20-30-37...1139
BUCKET POSITIONING CYLINDER (Cont'd)...1140
Figure 20-30-38...1140
Figure 20-30-39...1140
Figure 20-30-40...1140
Figure 20-30-41...1140
1...1132
Bushing...1132
2...1132
Housing...1132
3...1132
Wear Ring...1132
4...1132
Seal...1132
5...1132
O-ring...1132
6...1132
Set Screw...1132
7...1132
Piston...1132
8...1132
Rod...1132
9...1132
Head Gland...1132
10...1132
Wiper...1132
11...1132
Grease Fitting...1132
EXTENSION CYLINDER...1141
Figure 20-40-1...1141
Figure 20-40-2...1141
Figure 20-40-3...1141
Figure 20-40-4...1141
EXTENSION CYLINDER (Cont'd)...1142
Figure 20-40-5...1142
Figure 20-40-6...1142
Figure 20-40-7...1142
Figure 20-40-8...1142
EXTENSION CYLINDER (CONT’D)...1143
Figure 20-40-9...1143
Figure 20-40-10...1143
Figure 20-40-11...1143
Figure 20-40-12...1143
EXTENSION CYLINDER (CONT’D)...1144
Figure 20-40-13...1144
Figure 20-40-14...1144
Figure 20-40-15...1144
Figure 20-40-16...1144
EXTENSION CYLINDER (CONT’D)...1145
Figure 20-40-17...1145
Figure 20-40-18...1145
Figure 20-40-19...1145
Figure 20-40-20...1145
EXTENSION CYLINDER (CONT’D)...1146
Figure 20-40-21...1146
Figure 20-40-22...1146
Figure 20-40-23...1146
Figure 20-40-24...1146
EXTENSION CYLINDER (CONT’D)...1147
Figure 20-40-25...1147
Figure 20-40-26...1147
Figure 20-40-27...1147
Figure 20-40-28...1147
EXTENSION CYLINDER (CONT’D)...1148
Figure 20-40-29...1148
Figure 20-40-30...1148
Figure 20-40-31...1148
Figure 20-40-32...1148
EXTENSION CYLINDER (CONT’D)...1149
Figure 20-40-33...1149
Figure 20-40-34...1149
Figure 20-40-35...1149
Figure 20-40-36...1149
EXTENSION CYLINDER (CONT’D)...1150
Figure 20-40-37...1150
Figure 20-40-38...1150
Figure 20-40-39...1150
Figure 20-40-40...1150
EXTENSION CYLINDER (CONT’D)...1151
Figure 20-40-41...1151
Figure 20-40-42...1151
Figure 20-40-43...1151
Figure 20-40-44...1151
EXTENSION CYLINDER (CONT’D)...1152
Figure 20-40-45...1152
EXTENSION CYLINDER (CONT’D)...1153
EXTENSION CYLINDER (Cont'd)...1154
Figure 20-40-46...1154
Figure 20-40-47...1154
Figure 20-40-48...1154
Figure 20-40-49...1154
EXTENSION CYLINDER (Cont'd)...1155
Figure 20-40-50...1155
Figure 20-40-51...1155
Figure 20-40-52...1155
Figure 20-40-53...1155
EXTENSION CYLINDER (Cont'd)...1156
Figure 20-40-54...1156
Figure 20-40-55...1156
Figure 20-40-56...1156
Figure 20-40-57...1156
EXTENSION CYLINDER (Cont'd)...1157
Figure 20-40-58...1157
Figure 20-40-59...1157
Figure 20-40-60...1157
Figure 20-40-61...1157
EXTENSION CYLINDER (Cont'd)...1158
Figure 20-40-62...1158
Figure 20-40-63...1158
Figure 20-40-64...1158
Figure 20-40-65...1158
EXTENSION CYLINDER (CONT’D)...1159
Figure 20-40-66...1159
Figure 20-40-67...1159
Figure 20-40-68...1159
Figure 20-40-69...1159
EXTENSION CYLINDER (Cont'd)...1160
Figure 20-40-70...1160
Figure 20-40-71...1160
Figure 20-40-72...1160
Figure 20-40-73...1160
EXTENSION CYLINDER (Cont'd)...1161
Figure 20-40-74...1161
Figure 20-40-75...1161
Figure 20-40-76...1161
Figure 20-40-77...1161
EXTENSION CYLINDER (Cont'd)...1162
Figure 20-40-78...1162
Figure 20-40-79...1162
Figure 20-40-80...1162
TILT CYLINDER...1163
Figure 20-50-1...1163
Figure 20-50-2...1163
Figure 20-50-3...1163
Figure 20-50-4...1163
TILT CYLINDER (CONT’D)...1164
TILT CYLINDER (Cont'd)...1165
Figure 20-50-5...1165
Figure 20-50-6...1165
Figure 20-50-7...1165
Figure 20-50-8...1165
TILT CYLINDER (Cont'd)...1166
Figure 20-50-9...1166
Figure 20-50-10...1166
Figure 20-50-11...1166
Figure 20-50-12...1166
TILT CYLINDER (Cont'd)...1167
Figure 20-50-13...1167
Figure 20-50-14...1167
Figure 20-50-15...1167
Figure 20-50-16...1167
TILT CYLINDER (Cont'd)...1168
Figure 20-50-17...1168
Figure 20-50-18...1168
Figure 20-50-19...1168
Figure 20-50-20...1168
TILT CYLINDER (Cont'd)...1169
Figure 20-50-21...1169
Figure 20-50-22...1169
Figure 20-50-23...1169
Figure 20-50-24...1169
TILT CYLINDER (Cont'd)...1170
Figure 20-50-25...1170
Figure 20-50-26...1170
Figure 20-50-27...1170
Figure 20-50-28...1170
TILT CYLINDER (Cont'd)...1171
Figure 20-50-29...1171
Figure 20-50-30...1171
Figure 20-50-31...1171
Figure 20-50-32...1171
TILT CYLINDER (Cont'd)...1172
Figure 20-50-33...1172
Figure 20-50-34...1172
Figure 20-50-35...1172
STEERING CYLINDER (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...1173
Figure 20-60-1...1173
Figure 20-60-2...1173
Figure 20-60-3...1173
Figure 20-60-4...1173
STEERING CYLINDER (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1174
Figure 20-60-5...1174
Figure 20-60-6...1174
Figure 20-60-7...1174
Figure 20-60-8...1174
STEERING CYLINDER (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1175
Parts Identification...1175
STEERING CYLINDER (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1176
Figure 20-60-9...1176
Figure 20-60-10...1176
Figure 20-60-11...1176
Figure 20-60-12...1176
STEERING CYLINDER (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1177
Figure 20-60-13...1177
Figure 20-60-14...1177
Figure 20-60-15...1177
Figure 20-60-16...1177
STEERING CYLINDER (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1178
Figure 20-60-17...1178
Figure 20-60-18...1178
Figure 20-60-19...1178
Figure 20-60-20...1178
STEERING CYLINDER (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)(CONT’D)...1179
Figure 20-60-21...1179
Figure 20-60-22...1179
Figure 20-60-23...1179
Figure 20-60-24...1179
STEERING CYLINDER (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1180
Figure 20-60-25...1180
Figure 20-60-26...1180
Figure 20-60-27...1180
Figure 20-60-28...1180
STEERING CYLINDER (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1181
Figure 20-60-29...1181
Figure 20-60-30...1181
Figure 20-60-31...1181
Figure 20-60-32...1181
STEERING CYLINDER (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1182
Figure 20-60-33...1182
Figure 20-60-34...1182
Figure 20-60-35...1182
Figure 20-60-36...1182
STEERING CYLINDER (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1183
Figure 20-60-37...1183
Figure 20-60-38...1183
STEERING CYLINDER (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above)...1185
Figure 20-61-2...1185
Figure 20-61-3...1185
Figure 20-61-4...1185
STEERING CYLINDER (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1186
Figure 20-61-5...1186
Figure 20-61-6...1186
Figure 20-61-7...1186
Figure 20-61-8...1186
STEERING CYLINDER (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1187
Figure 20-61-9...1187
Figure 20-61-10...1187
Figure 20-61-11...1187
Figure 20-61-12...1187
STEERING CYLINDER (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1188
Figure 20-61-13...1188
Figure 20-61-14...1188
STEERING CYLINDER (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1189
Figure 20-61-15...1189
Figure 20-61-16...1189
Figure 20-61-17...1189
Figure 20-61-18...1189
STEERING CYLINDER (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1190
Figure 20-61-19...1190
STEERING CYLINDER (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1191
Figure 20-61-20...1191
Figure 20-61-21...1191
Figure 20-61-22...1191
Figure 20-61-23...1191
STEERING CYLINDER (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1192
Figure 20-61-24...1192
Figure 20-61-25...1192
Figure 20-61-26...1192
Figure 20-61-27...1192
STEERING CYLINDER (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1193
Figure 20-61-28...1193
Figure 20-61-29...1193
Figure 20-61-30...1193
STEERING CYLINDER (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...1195
Figure 20-62-1...1195
Figure 20-62-2...1195
Figure 20-62-3...1195
Figure 20-62-4...1195
STEERING CYLINDER (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1196
Figure 20-62-5...1196
Figure 20-62-6...1196
Figure 20-62-7...1196
Figure 20-62-8...1196
STEERING CYLINDER (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1197
Parts Identification...1197
STEERING CYLINDER (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1198
Figure 20-62-9...1198
Figure 20-62-10...1198
Figure 20-62-11...1198
Figure 20-62-12...1198
STEERING CYLINDER (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1199
Figure 20-62-13...1199
Figure 20-62-14...1199
Figure 20-62-15...1199
Figure 20-62-16...1199
STEERING CYLINDER (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1200
Figure 20-62-17...1200
Figure 20-62-18...1200
Figure 20-62-19...1200
Figure 20-62-20...1200
STEERING CYLINDER (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1201
Figure 20-62-21...1201
Figure 20-62-22...1201
Figure 20-62-23...1201
Figure 20-62-24...1201
STEERING CYLINDER (REAR) (For S/N 3628 12000 and below, S/N 3629 12000 and below) (Cont'd)...1202
Figure 20-62-25...1202
Figure 20-62-26...1202
Figure 20-62-27...1202
Figure 20-62-28...1202
STEERING CYLINDER (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1203
Figure 20-62-29...1203
Figure 20-62-30...1203
Figure 20-62-31...1203
Figure 20-62-32...1203
STEERING CYLINDER (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1204
Figure 20-62-33...1204
Figure 20-62-34...1204
Figure 20-62-35...1204
Figure 20-62-36...1204
STEERING CYLINDER (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1205
Figure 20-62-37...1205
Figure 20-62-38...1205
STEERING CYLINDER (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above)...1207
Figure 20-63-1...1207
Figure 20-63-2...1207
Figure 20-63-3...1207
Figure 20-63-4...1207
STEERING CYLINDER (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1208
Figure 20-63-5...1208
Figure 20-63-6...1208
Figure 20-63-7...1208
Figure 20-63-8...1208
STEERING CYLINDER (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1209
Figure 20-63-9...1209
Figure 20-63-10...1209
Figure 20-63-11...1209
Figure 20-63-12...1209
STEERING CYLINDER (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1210
Figure 20-63-13...1210
Figure 20-63-14...1210
STEERING CYLINDER (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1211
Figure 20-63-15...1211
Figure 20-63-16...1211
Figure 20-63-17...1211
Figure 20-63-18...1211
STEERING CYLINDER (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1212
Figure 20-63-19...1212
STEERING CYLINDER (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1213
Figure 20-63-20...1213
Figure 20-63-21...1213
Figure 20-63-22...1213
Figure 20-63-23...1213
STEERING CYLINDER (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1214
Figure 20-63-24...1214
Figure 20-63-25...1214
Figure 20-63-26...1214
Figure 20-63-27...1214
STEERING CYLINDER (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1215
Figure 20-63-28...1215
Figure 20-63-29...1215
Figure 20-63-30...1215
DRIVE BOX (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...1217
Parts Identification...1217
DRIVE BOX (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1218
Figure 20-70-1...1218
Figure 20-70-2...1218
Figure 20-70-3...1218
Figure 20-70-4...1218
DRIVE BOX (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1219
Figure 20-70-5...1219
Figure 20-70-6...1219
Figure 20-70-7...1219
DRIVE BOX (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1220
Figure 20-70-8...1220
Figure 20-70-9...1220
Figure 20-70-10...1220
Figure 20-70-11...1220
DRIVE BOX (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1221
Figure 20-70-12...1221
Figure 20-70-13...1221
Figure 20-70-14...1221
DRIVE BOX (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1222
Figure 20-70-15...1222
Figure 20-70-16...1222
Figure 20-70-17...1222
DRIVE BOX (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1223
Figure 20-70-18...1223
Figure 20-70-19...1223
Figure 20-70-20...1223
Figure 20-70-21...1223
DRIVE BOX (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1224
Figure 20-70-22...1224
Figure 20-70-23...1224
Figure 20-70-24...1224
Figure 20-70-25...1224
DRIVE BOX (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1225
Figure 20-70-26...1225
Figure 20-70-27...1225
Figure 20-70-28...1225
Figure 20-70-29...1225
DRIVE BOX (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1226
Figure 20-70-30...1226
Figure 20-70-31...1226
Figure 20-70-32...1226
DRIVE BOX (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1227
Figure 20-70-33...1227
Figure 20-70-34...1227
Figure 20-70-35...1227
Figure 20-70-36...1227
DRIVE BOX (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1228
Figure 20-70-37...1228
Figure 20-70-38...1228
Figure 20-70-39...1228
Figure 20-70-40...1228
DRIVE BOX (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1229
Figure 20-70-41...1229
Figure 20-70-42...1229
Figure 20-70-43...1229
DRIVE BOX (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1230
Figure 20-70-44...1230
Figure 20-70-45...1230
Figure 20-70-46...1230
Figure 20-70-47...1230
DRIVE BOX (For S/N 362812001 and Above, S/N 362912001 and Above)...1231
Parts Identification...1231
Figure 20-71-1...1231
DRIVE BOX (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1232
Figure 20-71-2...1232
Figure 20-71-3...1232
Figure 20-71-4...1232
Figure 20-71-5...1232
DRIVE BOX (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1233
Figure 20-71-6...1233
Figure 20-71-7...1233
Figure 20-71-8...1233
Figure 20-71-9...1233
DRIVE BOX (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1234
Figure 20-71-10...1234
Figure 20-71-11...1234
Figure 20-71-12...1234
DRIVE BOX (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1235
Figure 20-71-13...1235
Figure 20-71-14...1235
Figure 20-71-15...1235
Figure 20-71-16...1235
DRIVE BOX (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1236
Figure 20-71-17...1236
Figure 20-71-18...1236
Figure 20-71-19...1236
Figure 20-71-20...1236
DRIVE BOX (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1237
Figure 20-71-21...1237
Figure 20-71-22...1237
Figure 20-71-23...1237
Figure 20-71-24...1237
DRIVE BOX (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1238
Figure 20-71-25...1238
Figure 20-71-26...1238
Figure 20-71-27...1238
Figure 20-71-28...1238
special tools...1239
MAIN RELIEF VALVE...1241
Figure 20-20-1...1241
Figure 20-80-2...1241
Figure 20-80-3...1241
MAIN RELIEF VALVE (CONT’D)...1242
Figure 20-80-4...1242
Figure 20-80-5...1242
MAIN RELIEF VALVE (CONT’D)...1243
Figure 20-80-6...1243
QUICK TACH CYLINDER...1245
Figure 20-90-1...1245
Figure 20-90-2...1245
Figure 20-90-3...1245
Figure 20-90-4...1245
QUICK TACH CYLINDER (Cont'd)...1246
Figure 20-90-5...1246
Figure 20-90-6...1246
Figure 20-90-7...1246
Figure 20-90-8...1246
QUICK TACH CYLINDER (Cont'd)...1247
Parts Identification...1247
QUICK TACH CYLINDER (Cont'd)...1248
Figure 20-90-9...1248
Figure 20-90-10...1248
Figure 20-90-11...1248
Figure 20-90-12...1248
QUICK TACH CYLINDER (Cont'd)...1249
Figure 20-90-13...1249
Figure 20-90-14...1249
Figure 20-90-15...1249
Figure 20-90-16...1249
QUICK TACH CYLINDER (Cont'd)...1250
Figure 20-90-17...1250
Figure 20-90-18...1250
Figure 20-90-19...1250
QUICK TACH CYLINDER (Cont'd)...1251
Figure 20-90-20...1251
Figure 20-90-21...1251
Figure 20-90-22...1251
Figure 20-90-23...1251
QUICK TACH CYLINDER (Cont'd)...1252
Figure 20-90-24...1252
Figure 20-90-25...1252
Figure 20-90-26...1252
FRAME LEVELING CYLINDER...1253
Figure 20-100-2...1253
Figure 20-100-3...1253
FRAME LEVELING CYLINDER (CONT’D)...1254
Figure 20-100-4...1254
Figure 20-100-5...1254
FRAME LEVELING CYLINDER (CONT’D)...1255
Figure 20-100-2...1255
Figure 20-100-3...1255
Figure 20-100-4...1255
FRAME LEVELING CYLINDER (CONT’D)...1256
FRAME LEVELING CYLINDER (CONT’D)...1257
Figure 20-100-5...1257
Figure 20-100-6...1257
Figure 20-100-7...1257
Figure 20-100-8...1257
FRAME LEVELING CYLINDER (CONT’D)...1258
Figure 20-100-9...1258
Figure 20-100-10...1258
Figure 20-100-11...1258
Figure 20-100-12...1258
FRAME LEVELING CYLINDER (CONT’D)...1259
Figure 20-100-13...1259
Figure 20-100-14...1259
Figure 20-100-15...1259
Figure 20-100-16...1259
FRAME LEVELING CYLINDER (CONT’D)...1260
Figure 20-100-17...1260
Figure 20-100-18...1260
Figure 20-100-19...1260
Figure 20-100-20...1260
FRAME LEVELING CYLINDER (CONT’D)...1261
Figure 20-100-21...1261
Figure 20-100-22...1261
Figure 20-100-23...1261
FRAME LEVELING CYLINDER (CONT’D)...1262
Figure 20-100-24...1262
Figure 20-100-25...1262
Figure 20-100-26...1262
Figure 20-100-27...1262
FRAME LEVELING CYLINDER (CONT’D)...1263
Figure 20-100-28...1263
Figure 20-100-29...1263
Figure 20-100-30...1263
Figure 20-100-31...1263
FRAME LEVELING CYLINDER (CONT’D)...1264
Figure 20-100-32...1264
Figure 20-100-33...1264
Figure 20-100-34...1264
Figure 20-100-35...1264
FRAME LEVELING CYLINDER (CONT’D)...1265
Figure 20-100-36...1265
Figure 20-100-37...1265
Figure 20-100-38...1265
Figure 20-100-39...1265
FRAME LEVELING CYLINDER (CONT’D)...1266
Figure 20-100-40...1266
Figure 20-100-41...1266
Figure 20-100-42...1266
Figure 20-100-43...1266
FRAME LEVELING CYLINDER (CONT’D)...1267
Figure 20-100-44...1267
Figure 20-100-45...1267
STEERING MODE VALVE BLOCK...1269
Figure 20-110-1...1269
Figure 20-110-2...1269
STEERING MODE VALVE BLOCK (CONT’D)...1270
Figure 20-110-3...1270
Figure 20-110-4...1270
STEERING MODE VALVE BLOCK (CONT’D)...1271
STEERING MODE VALVE BLOCK (Cont'd)...1272
Figure 20-110-5...1272
Figure 20-110-6...1272
Figure 20-110-7...1272
Figure 20-110-8...1272
STEERING MODE VALVE BLOCK (Cont'd)...1273
Figure 20-110-9...1273
Figure 20-110-10...1273
Figure 20-110-11...1273
Figure 20-110-12...1273
STEERING MODE VALVE BLOCK (Cont'd)...1274
Figure 20-110-13...1274
Figure 20-110-14...1274
Figure 20-110-15...1274
Figure 20-110-16...1274
STEERING MODE VALVE BLOCK (Cont'd)...1275
Figure 20-110-17...1275
Figure 20-110-18...1275
Figure 20-110-19...1275
Figure 20-110-20...1275
STEERING MODE VALVE BLOCK (Cont'd)...1276
Figure 20-110-21...1276
Figure 20-110-22...1276
BRAKE VALVE...1277
Figure 20-120-1...1277
Figure 20-120-2...1277
Figure 20-120-3...1277
Figure 20-120-4...1277
BRAKE VALVE (CONT’D)...1278
Figure 20-120-5...1278
Figure 20-120-6...1278
Figure 20-120-7...1278
Figure 20-120-8...1278
BRAKE VALVE (CONT’D)...1279
Figure 20-120-9...1279
Figure 20-120-10...1279
Figure 20-120-11...1279
Figure 20-120-12...1279
BRAKE VALVE (CONT’D)...1280
Figure 20-120-13...1280
Figure 20-120-14...1280
Figure 20-120-15...1280
GEAR PUMP...1281
Figure 20-130-1...1281
Figure 20-130-2...1281
Figure 20-130-3...1281
GEAR PUMP (Cont'd)...1282
Figure 20-130-4...1282
Figure 20-130-5...1282
Figure 20-130-6...1282
Figure 20-130-7...1282
GEAR PUMP (Cont'd)...1283
Figure 20-130-8...1283
GEAR PUMP (CONT’D)...1284
GEAR PUMP (Cont'd)...1285
Figure 20-130-9...1285
Figure 20-130-10...1285
Figure 20-130-11...1285
Figure 20-130-12...1285
GEAR PUMP (Cont'd)...1286
Figure 20-130-13...1286
Figure 20-130-14...1286
Figure 20-130-15...1286
Figure 20-130-16...1286
GEAR PUMP (Cont'd)...1287
Figure 20-130-17...1287
Figure 20-130-18...1287
Figure 20-130-19...1287
Figure 20-130-20...1287
GEAR PUMP (Cont'd)...1288
Figure 20-130-21...1288
Figure 20-130-22...1288
Figure 20-130-23...1288
Figure 20-130-24...1288
GEAR PUMP (Cont'd)...1289
Figure 20-130-25...1289
Figure 20-130-26...1289
Figure 20-130-27...1289
Figure 20-130-28...1289
1...1284
Fitting...1284
2...1284
O-ring...1284
3...1284
Spring...1284
4...1284
Spring Seat...1284
5...1284
Spool...1284
6...1284
Screen...1284
7...1284
Orifice Spool...1284
8...1284
Bolt...1284
9...1284
Housing...1284
10...1284
Plug...1284
11...1284
Bolt...1284
12...1284
Washer...1284
13...1284
Cover...1284
14...1284
Seal Ring...1284
15...1284
Housing...1284
16...1284
Backup Ring...1284
17...1284
Seal Ring...1284
18...1284
Holder...1284
19...1284
Gear...1284
20...1284
Drive Shaft...1284
21...1284
Mount Plate...1284
22...1284
Thrust Plate...1284
23...1284
Mount Plate...1284
24...1284
Seal...1284
25...1284
Snap ring...1284
FAN MOTOR...1291
Figure 20-140-1...1291
Figure 20-140-2...1291
Figure 20-140-3...1291
Figure 20-140-4...1291
FAN MOTOR (CONT’D)...1292
Figure 20-140-5...1292
Figure 20-140-6...1292
Figure 20-140-7...1292
Figure 20-140-8...1292
FAN MOTOR (CONT’D)...1293
Figure 20-140-9...1293
Figure 20-140-10...1293
Figure 20-140-11...1293
Figure 20-140-12...1293
FAN MOTOR (CONT’D)...1294
Figure 20-140-13...1294
FAN MOTOR (CONT’D)...1295
FAN MOTOR (CONT’D)...1296
Figure 20-140-14...1296
Figure 20-140-15...1296
Figure 20-140-16...1296
FAN MOTOR (CONT’D)...1297
Figure 20-140-17...1297
Figure 20-140-18...1297
Figure 20-140-19...1297
Figure 20-140-20...1297
FAN MOTOR (CONT’D)...1298
Figure 20-140-21...1298
Figure 20-140-22...1298
Figure 20-140-23...1298
FAN MOTOR (CONT’D)...1299
Figure 20-140-24...1299
Figure 20-140-25...1299
Figure 20-140-26...1299
Figure 20-140-27...1299
FAN MOTOR (CONT’D)...1300
Figure 20-140-28...1300
Figure 20-140-29...1300
Figure 20-140-30...1300
Figure 20-140-31...1300
FAN MOTOR (CONT’D)...1301
Figure 20-140-32...1301
Figure 20-140-33...1301
Figure 20-140-34...1301
HYDRAULIC RESERVOIR...1303
Figure 20-150-1...1303
Figure 20-150-2...1303
Figure 20-150-3...1303
Figure 20-150-4...1303
HYDRAULIC RESERVOIR (CONT’D)...1304
Figure 20-150-5...1304
Figure 20-150-6...1304
Figure 20-150-7...1304
Figure 20-150-8...1304
STEERING VALVE...1305
Figure 20-160-1...1305
Figure 20-160-2...1305
STEERING VALVE (CONT’D)...1306
STEERING VALVE (Cont'd)...1307
Figure 20-160-3...1307
Figure 20-160-4...1307
Figure 20-160-5...1307
Figure 20-160-6...1307
Figure 20-160-7...1307
STEERING VALVE (Cont'd)...1308
Figure 20-160-8...1308
Figure 20-160-9...1308
Figure 20-160-10...1308
Figure 20-160-11...1308
STEERING VALVE (Cont'd)...1309
Figure 20-160-12...1309
Figure 20-160-13...1309
Figure 20-160-14...1309
Figure 20-160-15...1309
STEERING VALVE (Cont'd)...1310
Figure 20-160-16...1310
Figure 20-160-17...1310
Figure 20-160-18...1310
Figure 20-160-19...1310
STEERING VALVE (Cont'd)...1311
Figure 20-160-20...1311
Figure 20-160-21...1311
Figure 20-160-22...1311
Figure 20-160-23...1311
STEERING VALVE (Cont'd)...1312
Figure 20-160-24...1312
Figure 20-160-25...1312
Figure 20-160-26...1312
Figure 20-160-27...1312
STEERING VALVE (Cont'd)...1313
Figure 20-160-28...1313
Figure 20-160-29...1313
Figure 20-160-30...1313
Figure 20-160-31...1313
STEERING VALVE (Cont'd)...1314
Figure 20-160-32...1314
Figure 20-160-33...1314
Figure 20-160-34...1314
Figure 20-160-35...1314
STEERING VALVE (Cont'd)...1315
Figure 20-160-36...1315
Figure 20-160-37...1315
Figure 20-160-38...1315
Figure 20-160-39...1315
Figure 20-160-40...1315
STEERING VALVE (Cont'd)...1316
Figure 20-160-41...1316
Figure 20-160-42...1316
Figure 20-160-43...1316
Figure 20-160-44...1316
STEERING VALVE (Cont'd)...1317
Figure 20-160-45...1317
Figure 20-160-46...1317
Figure 20-160-47...1317
Figure 20-160-48...1317
STEERING VALVE (Cont'd)...1318
Figure 20-160-49...1318
Figure 20-160-50...1318
Figure 20-160-51...1318
Figure 20-160-52...1318
STEERING VALVE (Cont'd)...1319
Figure 20-160-53...1319
HYDRAULIC CONTROL VALVE...1321
HYDRAULIC CONTROL VALVE (CONT’D)...1322
Figure 170-10-1...1322
Figure 20-170-2...1322
1. Locate the telescoping valve section (Item 1) [Figure 20-170-2] on the control valve...1322
HYDRAULIC CONTROL VALVE (CONT’D)...1323
Figure 20-170-3...1323
2. A test harness (Item 1) [Figure 20-170-3] (MEL 1609: p/n 6679457) must be installed in between the male and female connector (Item 2) [Figure 20-170-3] of the telescoping valve section...1323
3. Connect the groundlead (-) of the multimeter to plug 2 (white) of the testharness...1323
4. With the engine OFF, the key in the run position, check that the battery voltage is at least 12 volts or higher by checking the voltage between plug 2 (white) and plug 1 (red) of the test harness...1323
5. With the engine OFF, the key in the run position, check that the regulated voltage on the controller connector is 5 volts by checking the voltage between plug 2 (white) and plug 4 (blue) of the test harness...1323
Figure 20-170-4...1323
6. With the telescopic function switch (Item 1) [Figure 20-170-4] in the minimum (back) position check that the voltage between plug 2 (white) and plug 3 (grey/ black) of the test harness is 0.9 volts...1323
7. With the telescopic function switch (Item 1) [Figure 20-170-4] in the neutral (middle) position check that the voltage between plug 2 (white) and plug 3 (grey/ black) of the test harness is 2.5 volts...1323
8. With the telescopic function switch (Item 1) [Figure 20-170-4] in the maximum (forward) position check that the voltage between plug 2 (white) and plug 3 (grey/black) of the test harness) is 4.1 volts...1323
HYDRAULIC CONTROL VALVE (CONT’D)...1324
Figure 20-170-5...1324
9. Locate the test fitting (Item 1) [Figure 20-170-5] and remove the cap...1324
Figure 20-170-6...1324
10. Install a 1000 PSI (70 bar) gauge on the test fitting [Figure 20-170-6]...1324
11. Start the engine, lower the restraint bar (if equipped) and run the engine at 2200 RPM. Record the pressure. The pressure at the gauge should be 508 PSI (35 bar) maximum...1324
12. Remove the gauge...1324
Figure 20-170-7...1324
13. Remove the hose (Item 1) [Figure 20-170-7] from the control valve, and install a tee fitting...1324
Figure 20-170-8...1324
14. Install a 500 PSI (35 bar) gauge on the tee fitting [Figure 20-170-8]...1324
15. Start the engine, lower the restraint bar (if equipped) and run the engine at 2200 RPM. Record the pressure. The pressure at the gauge should be 22 PSI (1,5 bar) maximum...1324
16. Remove the gauge...1324
HYDRAULIC CONTROL VALVE (CONT’D)...1325
Figure 20-170-9...1325
17. With adequate room in front of the machine, start the engine, lower the restraint bar (if equipped) and run the engine at 22...1325
Figure 20-170-10...1325
18. If the telescopic function does not work, with the engine running unplug the controller connector (Item 1) [Figure 20-170-10] and plug it back in...1325
Figure 20-170-11...1325
19. If the telescopic function does not work, remove the two screws (Item 1) and remove the cover (Item 2) [Figure 20-170-11]...1325
20. Start the engine, lower the restraint bar (if equipped) and run the engine at 2200 RPM...1325
Figure 20-170-12...1325
21. Manually push and pull the spool (Item 1) [Figure 20- 170-12] to test the movement of the telescopic function in both directions...1325
HYDRAULIC CONTROL VALVE (CONT’D)...1326
Figure 20-170-13...1326
Figure 20-170-14...1326
1. Locate the auxiliary valve section (Item 1) [Figure 20- 170-14] on the control valve...1326
HYDRAULIC CONTROL VALVE (CONT’D)...1327
Figure 20-170-15...1327
2. A test harness (Item 1) [Figure 20-170-3] (MEL 1609: p/n 6679457) must be installed in between the male and female connector (Item 2) [Figure 20-170-3] of the telescoping valve section...1327
3. Connect the groundlead (-) of the multimeter to plug 2 (white) of the testharness...1327
4. With the engine OFF, the key in the run position, check that the battery voltage is at least 12 volts or higher by checking the voltage between plug 2 (white) and plug 1 (red) of the test harness...1327
5. With the engine OFF, the key in the run position, check that the regulated voltage on the controller connector is 5 volts by checking the voltage between plug 2 (white) and plug 4 (blue) of the test harness...1327
Figure 20-170-16...1327
6. With the auxiliary function switch (Item 1) [Figure 20- 170-4] in the minimum (back) position check that the voltage between plug 2 (white) and plug 3 (grey/black) of the test harness is 0.9 volts...1327
7. With the auxiliary function switch (Item 1) [Figure 20- 170-4] in the neutral (middle) position check that the voltage between plug 2 (white) and plug 3 (grey/black) of the test harness is 2.5 volts...1327
8. With the auxiliary function switch (Item 1) [Figure 20- 170-4] in the maximum (forward) position check that the voltage between plug 2 (white) and plug 3 (grey/ black) of the test harness) is 4.1 volts...1327
HYDRAULIC CONTROL VALVE (CONT’D)...1328
Figure 20-170-17...1328
9. Locate the test fitting (Item 1) [Figure 20-170-17] and remove the cap...1328
Figure 20-170-18...1328
10. Install a 1000 PSI (70 bar) gauge on the test fitting [Figure 20-170-18]...1328
11. Start the engine, lower the restraint bar (if equipped) and run the engine at 2200 RPM. Record the pressure. The pressure at the gauge should be 508 PSI (35 bar) maximum...1328
12. Remove the gauge...1328
Figure 20-170-19...1328
13. Remove the hose (Item 1) [Figure 20-170-19] from the control valve, and install a tee fitting...1328
Figure 20-170-20...1328
14. Install a 500 PSI (35 bar) gauge on the tee fitting [Figure 20-170-20]...1328
15. Start the engine, lower the restraint bar (if equipped) and run the engine at 2200 RPM. Record the pressure. The pressure at the gauge should be 22 PSI (1,5 bar) maximum...1328
16. Remove the gauge...1328
HYDRAULIC CONTROL VALVE (CONT’D)...1329
Figure 20-170-21...1329
17. With adequate room in front of the machine, start the engine, lower the restraint bar (if equipped) and run the engine at 22...1329
Figure 20-170-22...1329
18. If the auxiliary function does not work, with the engine running unplug the controller connector (Item 1) [Figure 20-170-22] and plug it back in...1329
Figure 20-170-23...1329
19. If the auxiliary function does not work, remove the two screws (Item 1) and remove the cover (Item 2) [Figure 20-170-23]...1329
20. Start the engine, lower the restraint bar (if equipped) and run the engine at 2200 RPM...1329
Figure 20-170-24...1329
21. Manually push and pull the spool (Item 1) [Figure 20- 170-24] to test the movement of the auxiliary function in both directions...1329
HYDRAULIC CONTROL VALVE (CONT’D)...1330
HYDRAULIC CONTROL VALVE (CONT’D)...1331
Figure 20-170-25...1331
Figure 20-170-26...1331
Figure 20-170-27...1331
HYDRAULIC CONTROL VALVE (CONT’D)...1332
Figure 20-170-28...1332
Figure 20-170-29...1332
Figure 20-170-30...1332
Figure 20-170-31...1332
HYDRAULIC CONTROL VALVE (CONT’D)...1333
Figure 20-170-32...1333
Figure 20-170-33...1333
Figure 20-170-34...1333
Figure 20-170-35...1333
HYDRAULIC CONTROL VALVE (CONT’D)...1334
Figure 20-170-36...1334
HYDRAULIC CONTROL VALVE (CONT’D)...1335
HYDRAULIC CONTROL VALVE (CONT’D)...1336
Figure 20-170-37...1336
Figure 20-170-38...1336
Figure 20-170-39...1336
HYDRAULIC CONTROL VALVE (CONT’D)...1337
Figure 20-170-40...1337
Figure 20-170-41...1337
Figure 20-170-42...1337
HYDRAULIC CONTROL VALVE (CONT’D)...1338
Figure 20-170-43...1338
Figure 20-170-44...1338
Figure 20-170-45...1338
Figure 20-170-46...1338
HYDRAULIC CONTROL VALVE (CONT’D)...1339
Figure 20-170-47...1339
Figure 20-170-48...1339
Figure 20-170-49...1339
Figure 20-170-50...1339
HYDRAULIC CONTROL VALVE (CONT’D)...1340
Figure 20-170-51...1340
Figure 20-170-52...1340
Figure 20-170-53...1340
Figure 20-170-54...1340
HYDRAULIC CONTROL VALVE (CONT’D)...1341
Figure 20-170-55...1341
Figure 20-170-56...1341
Figure 20-170-57...1341
Figure 20-170-58...1341
HYDRAULIC CONTROL VALVE (CONT’D)...1342
Figure 20-170-59...1342
Figure 20-170-60...1342
Figure 20-170-61...1342
Figure 20-170-62...1342
HYDRAULIC CONTROL VALVE (CONT’D)...1343
Figure 20-170-63...1343
Figure 20-170-64...1343
Figure 20-170-65...1343
Figure 20-170-66...1343
HYDRAULIC CONTROL VALVE (CONT’D)...1344
Figure 20-170-67...1344
Figure 20-170-68...1344
Figure 20-170-69...1344
Figure 20-170-70...1344
HYDRAULIC CONTROL VALVE (CONT’D)...1345
Figure 20-170-71...1345
Figure 20-170-72...1345
Figure 20-170-73...1345
Figure 20-170-74...1345
HYDRAULIC CONTROL VALVE (CONT’D)...1346
Figure 20-170-75...1346
Figure 20-170-76...1346
Figure 20-170-77...1346
Figure 20-170-78...1346
HYDRAULIC CONTROL VALVE (CONT’D)...1347
Figure 20-170-79...1347
Figure 20-170-80...1347
Figure 20-170-81...1347
Figure 20-170-82...1347
HYDRAULIC CONTROL VALVE (CONT’D)...1348
Figure 20-170-83...1348
Figure 20-170-84...1348
Figure 20-170-85...1348
Figure 20-170-86...1348
HYDRAULIC CONTROL VALVE (CONT’D)...1349
Figure 20-170-87...1349
Figure 20-170-88...1349
Figure 20-170-89...1349
Figure 20-170-90...1349
HYDRAULIC CONTROL VALVE (CONT’D)...1350
Figure 20-170-91...1350
Figure 20-170-92...1350
Figure 20-170-93...1350
Figure 20-170-94...1350
HYDRAULIC CONTROL VALVE (CONT’D)...1351
Figure 20-170-95...1351
Figure 20-170-96...1351
Figure 20-170-97...1351
Figure 20-170-98...1351
HYDRAULIC CONTROL VALVE (CONT’D)...1352
Figure 20-170-99...1352
Figure 20-170-100...1352
Figure 20-170-101...1352
Figure 20-170-102...1352
HYDRAULIC CONTROL VALVE (CONT’D)...1353
Figure 20-170-103...1353
Figure 20-170-104...1353
Figure 20-170-105...1353
Figure 20-170-106...1353
HYDRAULIC CONTROL VALVE (CONT’D)...1354
Figure 20-170-107...1354
Figure 20-170-108...1354
Figure 20-170-109...1354
Figure 20-170-110...1354
HYDRAULIC CONTROL VALVE (CONT’D)...1355
Figure 20-170-111...1355
Figure 20-170-112...1355
Figure 20-170-113...1355
Figure 20-170-114...1355
HYDRAULIC CONTROL VALVE (CONT’D)...1356
Figure 20-170-115...1356
Figure 20-170-116...1356
Figure 20-170-117...1356
Figure 20-170-118...1356
HYDRAULIC CONTROL VALVE (CONT’D)...1357
Figure 20-170-119...1357
Figure 20-170-120...1357
Figure 20-170-121...1357
Figure 20-170-122...1357
HYDRAULIC CONTROL VALVE (CONT’D)...1358
Figure 20-170-123...1358
Figure 20-170-124...1358
Figure 20-170-125...1358
Figure 20-170-126...1358
HYDRAULIC CONTROL VALVE (CONT’D)...1359
Figure 20-170-127...1359
Figure 20-170-128...1359
HYDRAULIC CONTROL VALVE (CONT’D)...1360
Figure 20-170-129...1360
Figure 20-170-130...1360
Figure 20-170-131...1360
Figure 20-170-132...1360
HYDRAULIC CONTROL VALVE (CONT’D)...1361
Figure 20-170-133...1361
Figure 20-170-134...1361
Figure 20-170-135...1361
Figure 20-170-136...1361
HYDRAULIC CONTROL VALVE (CONT’D)...1362
Figure 20-170-137...1362
Figure 20-170-138...1362
Figure 20-170-139...1362
Figure 20-170-140...1362
HYDRAULIC CONTROL VALVE (CONT’D)...1363
Figure 20-170-141...1363
Figure 20-170-142...1363
Figure 20-170-143...1363
Figure 20-170-144...1363
HYDRAULIC CONTROL VALVE (CONT’D)...1364
Figure 20-170-145...1364
Figure 20-170-146...1364
Figure 20-170-147...1364
HYDRAULIC CONTROL VALVE (CONT’D)...1365
Figure 20-170-148...1365
Figure 20-170-149...1365
Figure 20-170-150...1365
Figure 20-170-151...1365
HYDRAULIC CONTROL VALVE (CONT’D)...1366
Figure 20-170-152...1366
Figure 20-170-153...1366
Figure 20-170-154...1366
Figure 20-170-155...1366
HYDRAULIC CONTROL VALVE (CONT’D)...1367
Figure 20-170-156...1367
Figure 20-170-157...1367
Figure 20-170-158...1367
Figure 20-170-159...1367
HYDRAULIC CONTROL VALVE (CONT’D)...1368
Figure 20-170-160...1368
Figure 20-170-161...1368
Figure 20-170-162...1368
Figure 20-170-163...1368
HYDRAULIC CONTROL VALVE (CONT’D)...1369
Figure 20-170-164...1369
Figure 20-170-165...1369
Figure 20-170-166...1369
Figure 20-170-167...1369
HYDRAULIC CONTROL VALVE (CONT’D)...1370
Figure 20-170-168...1370
Figure 20-170-169...1370
Figure 20-170-170...1370
Figure 20-170-171...1370
HYDRAULIC CONTROL VALVE (CONT’D)...1371
Figure 20-170-172...1371
Figure 20-170-173...1371
Figure 20-170-174...1371
Figure 20-170-175...1371
HYDRAULIC CONTROL VALVE (CONT’D)...1372
Figure 20-170-176...1372
Figure 20-170-177...1372
Figure 20-170-178...1372
Figure 20-170-179...1372
HYDRAULIC CONTROL VALVE (CONT’D)...1373
Figure 20-170-180...1373
Figure 20-170-181...1373
Figure 20-170-182...1373
Figure 20-170-183...1373
HYDRAULIC CONTROL VALVE (CONT’D)...1374
Figure 20-170-184...1374
Figure 20-170-185...1374
Figure 20-170-186...1374
PORT RELIEF VALVES...1375
Figure 20-171-2...1375
FLOW CONTROL VALVE...1377
Figure 20-172-2...1377
Figure 20-172-3...1377
JOYSTICK...1379
Figure 20-180-1...1379
Figure 20-180-2...1379
Figure 20-180-3...1379
JOYSTICK (CONT’D)...1380
Figure 20-180-4...1380
Figure 20-180-5...1381
PARKING BRAKE...1383
Figure 20-190-6...1383
Figure 20-190-7...1383
Figure 20-190-8...1383
Figure 20-190-9...1383
PARKING BRAKE (CONT’D)...1384
Figure 20-190-10...1384
Figure 20-190-11...1384
Figure 20-190-12...1384
Figure 20-190-13...1384
Figure 20-190-14...1384
PILOT PRESSURE LOCK OUT VALVE...1385
Figure 20-200-2...1385
Figure 20-200-3...1385
PILOT PRESSURE LOCK OUT VALVE (CONT’D)...1386
Figure 20-200-4...1386
Figure 20-200-5...1386
Figure 20-200-6...1386
PILOT PRESSURE LOCK OUT VALVE (CONT’D)...1387
Figure 20-200-7...1387
Figure 20-200-8...1387
Figure 20-200-9...1387
Figure 20-200-10...1387
PILOT PRESSURE LOCK OUT VALVE (CONT’D)...1388
Figure 20-200-11...1388
Figure 20-200-12...1388
ACCUMULATOR...1389
Figure 20-210-2...1389
Optional TOW VALVE...1391
Figure 20-220-1...1391
Figure 20-220-2...1391
Figure 20-220-3...1391
TOW VALVE (CONT’D)...1392
Figure 20-220-4...1392
Figure 20-220-5...1392
Figure 20-220-6...1392
Figure 20-220-7...1392
TOW VALVE (CONT’D)...1393
Figure 20-220-8...1393
Figure 20-220-9...1393
Figure 20-220-10...1393
TOW VALVE (CONT’D)...1394
Figure 20-220-11...1394
Figure 20-220-12...1394
Figure 20-220-13...1394
Figure 20-220-14...1394
TOW VALVE (CONT’D)...1395
Figure 20-220-15...1395
Figure 20-220-16...1395
Figure 20-220-17...1395
HYDROSTATIC SYSTEM...1397
HYDROSTATIC DRIVE MOTOR 30-30-1...1397
Assembly 30-30-22...1397
Disassembly 30-30-5...1397
Inspection 30-30-20...1397
Parts Identification 30-30-2...1397
Removal And Installation 30-30-1...1397
HYDROSTATIC PUMP 30-40-1...1397
Assembly 30-40-25...1397
Charge pressure checking procedure 30-40-40...1397
Charge pressure adjusting procedure 30-40-40...1397
Disassembly 30-40-9...1397
Inspection 30-40-21...1397
Parts Identification 30-40-4...1397
Removal And Installation 30-40-1...1397
HYDROSTATIC SYSTEM INFORMATION 30-10-1...1397
Replenishing Valve Function 30-10-2...1397
Troubleshooting Chart 30-10-1...1397
OIL COOLER 30-20-1...1397
Description 30-20-1...1397
HYDROSTATIC SYSTEM INFORMATION...1399
HYDROSTATIC SYSTEM INFORMATION (CONT’D)...1400
Figure 30-10-1...1400
1. To give replacement fluid to the low pressure side of the hydrostatic circuit. Replacement fluid is needed because of normal internal leakage and the controlled flow to the oil cooler for cooling; Function 1 [Figure 30-10-1]...1400
2. To keep high pressure fluid out of the low pressure side of the hydrostatic circuitry; Function 2 [Figure 30- 10-1]...1400
OIL COOLER...1401
HYDROSTATIC DRIVE MOTOR...1403
Figure 30-30-1...1403
HYDROSTATIC DRIVE MOTOR (Cont'd)...1404
Parts Identification...1404
HYDROSTATIC DRIVE MOTOR (Cont'd)...1405
Parts Identification (Cont’d)...1405
HYDROSTATIC DRIVE MOTOR (Cont'd)...1406
Parts Identification (Cont’d)...1406
HYDROSTATIC DRIVE MOTOR (Cont'd)...1407
Figure 30-30-2...1407
Figure 30-30-3...1407
Figure 30-30-4...1407
Figure 30-30-5...1407
HYDROSTATIC DRIVE MOTOR (Cont'd)...1408
Figure 30-30-6...1408
Figure 30-30-7...1408
Figure 30-30-8...1408
Figure 30-30-9...1408
HYDROSTATIC DRIVE MOTOR (Cont'd)...1409
Figure 30-30-10...1409
Figure 30-30-11...1409
Figure 30-30-12...1409
Figure 30-30-13...1409
HYDROSTATIC DRIVE MOTOR (Cont'd)...1410
Figure 30-30-14...1410
Figure 30-30-15...1410
Figure 30-30-16...1410
Figure 30-30-17...1410
HYDROSTATIC DRIVE MOTOR (Cont'd)...1411
Figure 30-30-18...1411
Figure 30-30-19...1411
Figure 30-30-20...1411
Figure 30-30-21...1411
HYDROSTATIC DRIVE MOTOR (Cont'd)...1412
Figure 30-30-22...1412
Figure 30-30-23...1412
Figure 30-30-24...1412
Figure 30-30-25...1412
HYDROSTATIC DRIVE MOTOR (Cont'd)...1413
Figure 30-30-26...1413
Figure 30-30-27...1413
Figure 30-30-28...1413
Figure 30-30-29...1413
HYDROSTATIC DRIVE MOTOR (Cont'd)...1414
Figure 30-30-30...1414
Figure 30-30-31...1414
Figure 30-30-32...1414
Figure 30-30-33...1414
HYDROSTATIC DRIVE MOTOR (Cont'd)...1415
Figure 30-30-34...1415
Figure 30-30-35...1415
Figure 30-30-36...1415
Figure 30-30-37...1415
HYDROSTATIC DRIVE MOTOR (Cont'd)...1416
Figure 30-30-38...1416
Figure 30-30-39...1416
Figure 30-30-40...1416
Figure 30-30-41...1416
HYDROSTATIC DRIVE MOTOR (Cont'd)...1417
Figure 30-30-42...1417
Figure 30-30-43...1417
Figure 30-30-44...1417
Figure 30-30-45...1417
HYDROSTATIC DRIVE MOTOR (Cont'd)...1418
Figure 30-30-46...1418
Figure 30-30-47...1418
Figure 30-30-48...1418
Figure 30-30-49...1418
HYDROSTATIC DRIVE MOTOR (Cont'd)...1419
Figure 30-30-50...1419
Figure 30-30-51...1419
Figure 30-30-52...1419
Figure 30-30-53...1419
HYDROSTATIC DRIVE MOTOR (Cont'd)...1420
Figure 30-30-54...1420
Figure 30-30-55...1420
Figure 30-30-56...1420
Figure 30-30-57...1420
HYDROSTATIC DRIVE MOTOR (Cont'd)...1421
Figure 30-30-58...1421
Figure 30-30-59...1421
Figure 30-30-60...1421
Figure 30-30-61...1421
HYDROSTATIC DRIVE MOTOR (Cont'd)...1422
Figure 30-30-62...1422
Figure 30-30-63...1422
Figure 30-30-64...1422
HYDROSTATIC DRIVE MOTOR (Cont'd)...1423
Figure 30-30-65...1423
Figure 30-30-66...1423
Figure 30-30-67...1423
HYDROSTATIC DRIVE MOTOR (Cont'd)...1424
Figure 30-30-68...1424
Figure 30-30-69...1424
Figure 30-30-70...1424
Figure 30-30-71...1424
HYDROSTATIC DRIVE MOTOR (Cont'd)...1425
Figure 30-30-72...1425
Figure 30-30-73...1425
Figure 30-30-74...1425
Figure 30-30-75...1425
HYDROSTATIC DRIVE MOTOR (Cont'd)...1426
Figure 30-30-76...1426
Figure 30-30-77...1426
Figure 30-30-78...1426
Figure 30-30-79...1426
HYDROSTATIC DRIVE MOTOR (Cont'd)...1427
Figure 30-30-80...1427
Figure 30-30-81...1427
Figure 30-30-82...1427
Figure 30-30-83...1427
HYDROSTATIC DRIVE MOTOR (Cont'd)...1428
Figure 30-30-84...1428
Figure 30-30-85...1428
Figure 30-30-86...1428
Figure 30-30-87...1428
HYDROSTATIC DRIVE MOTOR (Cont'd)...1429
Figure 30-30-88...1429
Figure 30-30-89...1429
Figure 30-30-90...1429
Figure 30-30-91...1429
HYDROSTATIC DRIVE MOTOR (Cont'd)...1430
Figure 30-30-92...1430
Figure 30-30-93...1430
Figure 30-30-94...1430
Figure 30-30-95...1430
HYDROSTATIC DRIVE MOTOR (Cont'd)...1431
Figure 30-30-96...1431
Figure 30-30-97...1431
Figure 30-30-98...1431
Figure 30-30-99...1431
HYDROSTATIC DRIVE MOTOR (Cont'd)...1432
Figure 30-30-100...1432
Figure 30-30-101...1432
Figure 30-30-102...1432
Figure 30-30-103...1432
HYDROSTATIC DRIVE MOTOR (Cont'd)...1433
Figure 30-30-104...1433
Figure 30-30-105...1433
Figure 30-30-106...1433
Figure 30-30-107...1433
HYDROSTATIC DRIVE MOTOR (Cont'd)...1434
Figure 30-30-108...1434
Figure 30-30-109...1434
Figure 30-30-110...1434
Figure 30-30-111...1434
HYDROSTATIC DRIVE MOTOR (Cont'd)...1435
Figure 30-30-112...1435
Figure 30-30-113...1435
Figure 30-30-114...1435
Figure 30-30-115...1435
HYDROSTATIC DRIVE MOTOR (Cont'd)...1436
Figure 30-30-116...1436
Figure 30-30-117...1436
Figure 30-30-118...1436
Figure 30-30-119...1436
HYDROSTATIC DRIVE MOTOR (Cont'd)...1437
Figure 30-30-120...1437
Figure 30-30-121...1437
Figure 30-30-122...1437
Figure 30-30-123...1437
HYDROSTATIC DRIVE MOTOR (Cont'd)...1438
Figure 30-30-124...1438
Figure 30-30-125...1438
Figure 30-30-126...1438
Figure 30-30-127...1438
HYDROSTATIC DRIVE MOTOR (Cont'd)...1439
Figure 30-30-128...1439
Figure 30-30-129...1439
Figure 30-30-130...1439
Figure 30-30-131...1439
HYDROSTATIC DRIVE MOTOR (Cont'd)...1440
Figure 30-30-132...1440
Figure 30-30-133...1440
Figure 30-30-134...1440
Figure 30-30-135...1440
HYDROSTATIC PUMP...1441
Figure 30-40-1...1441
Figure 30-40-2...1441
Figure 30-40-3...1441
HYDROSTATIC PUMP (CONT’D)...1442
Figure 30-40-4...1442
Figure 30-40-5...1442
Figure 30-40-6...1442
Figure 30-40-7...1442
HYDROSTATIC PUMP (CONT’D)...1443
Figure 30-40-8...1443
Figure 30-40-9...1443
Figure 30-40-10...1443
HYDROSTATIC PUMP (Cont'd)...1444
Parts Identification...1444
HYDROSTATIC PUMP (Cont'd)...1445
Parts Identification (Cont’d)...1445
CUSTOMER PACKING LIST...1446
HYDROSTATIC PUMP (CONT’D)...1447
HYDROSTATIC PUMP (CONT’D)...1448
HYDROSTATIC PUMP (Cont'd)...1449
Figure 30-40-11...1449
Figure 30-40-12...1449
Figure 30-40-13...1449
Figure 30-40-14...1449
HYDROSTATIC PUMP (Cont'd)...1450
Figure 30-40-15...1450
Figure 30-40-16...1450
Figure 30-40-17...1450
Figure 30-40-18...1450
HYDROSTATIC PUMP (Cont'd)...1451
Figure 30-40-19...1451
Figure 30-40-20...1451
Figure 30-40-21...1451
Figure 30-40-22...1451
HYDROSTATIC PUMP (Cont'd)...1452
Figure 30-40-23...1452
Figure 30-40-24...1452
Figure 30-40-25...1452
Figure 30-40-26...1452
HYDROSTATIC PUMP (Cont'd)...1453
Figure 30-40-27...1453
Figure 30-40-28...1453
Figure 30-40-29...1453
Figure 30-40-30...1453
HYDROSTATIC PUMP (Cont'd)...1454
Figure 30-40-31...1454
Figure 30-40-32...1454
Figure 30-40-33...1454
Figure 30-40-34...1454
HYDROSTATIC PUMP (Cont'd)...1455
Figure 30-40-35...1455
Figure 30-40-36...1455
Figure 30-40-37...1455
Figure 30-40-38...1455
HYDROSTATIC PUMP (Cont'd)...1456
Figure 30-40-39...1456
Figure 30-40-40...1456
Figure 30-40-41...1456
Figure 30-40-42...1456
HYDROSTATIC PUMP (Cont'd)...1457
Figure 30-40-43...1457
Figure 30-40-44...1457
Figure 30-40-45...1457
Figure 30-40-46...1457
HYDROSTATIC PUMP (Cont'd)...1458
Figure 30-40-47...1458
Figure 30-40-48...1458
Figure 30-40-49...1458
Figure 30-40-50...1458
HYDROSTATIC PUMP (Cont'd)...1459
Figure 30-40-51...1459
Figure 30-40-52...1459
Figure 30-40-53...1459
Figure 30-40-54...1459
HYDROSTATIC PUMP (Cont'd)...1460
Figure 30-40-55...1460
Figure 30-40-56...1460
Figure 30-40-57...1460
HYDROSTATIC PUMP (Cont'd)...1461
Figure 30-40-58...1461
Figure 30-40-59...1461
Figure 30-40-60...1461
Figure 30-40-61...1461
HYDROSTATIC PUMP (Cont'd)...1462
Figure 30-40-62...1462
Figure 30-40-63...1462
Figure 30-40-64...1462
Figure 30-40-65...1462
HYDROSTATIC PUMP (Cont'd)...1463
Figure 30-40-66...1463
Figure 30-40-67...1463
Figure 30-40-68...1463
Figure 30-40-69...1463
HYDROSTATIC PUMP (Cont'd)...1464
Figure 30-40-70...1464
Figure 30-40-71...1464
Figure 30-40-72...1464
Figure 30-40-73...1464
HYDROSTATIC PUMP (Cont'd)...1465
Figure 30-40-74...1465
Figure 30-40-75...1465
Figure 30-40-76...1465
Figure 30-40-77...1465
HYDROSTATIC PUMP (Cont'd)...1466
Figure 30-40-78...1466
Figure 30-40-79...1466
Figure 30-40-80...1466
Figure 30-40-81...1466
HYDROSTATIC PUMP (Cont'd)...1467
Figure 30-40-82...1467
Figure 30-40-83...1467
Figure 30-40-84...1467
Figure 30-40-85...1467
HYDROSTATIC PUMP (Cont'd)...1468
Figure 30-40-86...1468
Figure 30-40-87...1468
Figure 30-40-88...1468
Figure 30-40-89...1468
HYDROSTATIC PUMP (Cont'd)...1469
Figure 30-40-90...1469
Figure 30-40-91...1469
Figure 30-40-92...1469
Figure 30-40-93...1469
HYDROSTATIC PUMP (Cont'd)...1470
Figure 30-40-94...1470
Figure 30-40-95...1470
Figure 30-40-96...1470
Figure 30-40-97...1470
HYDROSTATIC PUMP (Cont'd)...1471
Figure 30-40-98...1471
Figure 30-40-99...1471
Figure 30-40-100...1471
Figure 30-40-101...1471
HYDROSTATIC PUMP (Cont'd)...1472
Figure 30-40-102...1472
Figure 30-40-103...1472
Figure 30-40-104...1472
Figure 30-40-105...1472
HYDROSTATIC PUMP (Cont'd)...1473
Figure 30-40-106...1473
Figure 30-40-107...1473
Figure 30-40-108...1473
Figure 30-40-109...1473
HYDROSTATIC PUMP (Cont'd)...1474
Figure 30-40-110...1474
Figure 30-40-111...1474
Figure 30-40-112...1474
Figure 30-40-113...1474
HYDROSTATIC PUMP (Cont'd)...1475
Figure 30-40-114...1475
Figure 30-40-115...1475
Figure 30-40-116...1475
Figure 30-40-117...1475
HYDROSTATIC PUMP (Cont'd)...1476
Figure 30-40-118...1476
Figure 30-40-119...1476
Figure 30-40-120...1476
Figure 30-40-121...1476
HYDROSTATIC PUMP (Cont'd)...1477
Figure 30-40-122...1477
Figure 30-40-123...1477
Figure 30-40-124...1477
Figure 30-40-125...1477
HYDROSTATIC PUMP (Cont'd)...1478
Figure 30-40-126...1478
Figure 30-40-127...1478
Figure 30-40-128...1478
Figure 30-40-129...1478
HYDROSTATIC PUMP (Cont'd)...1479
Figure 30-40-130...1479
Figure 30-40-131...1479
HYDROSTATIC PUMP (Cont'd)...1480
Figure 30-40-132...1480
Figure 30-40-133...1480
1...1446
Key...1446
2...1446
Charge Pump Shaft...1446
3...1446
Pin...1446
4...1446
Wear Plate...1446
5...1446
Gears...1446
6...1446
Coupling...1446
7...1446
Seal...1446
8...1446
Charge Pump Cover...1446
9...1446
Retaining Plate...1446
10...1446
Bolt...1446
11...1446
O-Ring...1446
12...1446
Flange Adapter...1446
13...1446
Washer...1446
14...1446
Bolt...1446
15...1446
O-Ring...1446
1...1447
Valve Plate...1447
2...1447
Retaining Ring...1447
3...1447
Spring Retainer...1447
4...1447
Spring...1447
5...1447
Spring Seat...1447
6...1447
Cylinder...1447
7...1447
Bolt...1447
8...1447
Slipper Guide Bearing...1447
9...1447
Spacer...1447
10...1447
Slipper Guide...1447
11...1447
Piston...1447
12...1447
Bolt...1447
13...1447
Bolt...1447
14...1447
Block...1447
15...1447
Spring...1447
16...1447
Servo Arm...1447
17...1447
Pin...1447
18...1447
Washer...1447
19...1447
Swash Plate Guide...1447
20...1447
Pin...1447
21...1447
Housing...1447
22...1447
Swash Plate...1447
23...1447
Bearing Assembly...1447
24...1447
Pin...1447
25...1447
Housing...1447
1...1448
Snap Ring...1448
2...1448
Spring Guide...1448
3...1448
Spring...1448
4...1448
Spring Guide...1448
5...1448
Bolt...1448
6...1448
Bolt...1448
7...1448
Servo Spring Housing...1448
8...1448
Nut...1448
9...1448
Screw...1448
10...1448
Servo Cylinder...1448
11...1448
O-Ring...1448
12...1448
O-Ring...1448
13...1448
Nut...1448
14...1448
Nut...1448
15...1448
Bearing...1448
16...1448
Spacer...1448
17...1448
Snap Ring...1448
18...1448
Shaft...1448
19...1448
Piston Ring...1448
20...1448
O-Ring...1448
21...1448
Block...1448
22...1448
Servo Piston...1448
23...1448
O-Ring...1448
24...1448
O-Ring...1448
25...1448
Bolt...1448
26...1448
End Cap...1448
27...1448
Shim...1448
28...1448
Spring...1448
29...1448
Spring Seat...1448
30...1448
Guide Post...1448
31...1448
Leveler...1448
32...1448
O-ring...1448
33...1448
Inserts...1448
34...1448
Side Cover...1448
35...1448
Bolt...1448
36...1448
Nut...1448
37...1448
Plug...1448
DRIVE SYSTEM...1481
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) 40-20-1...1481
Axle Housing/Drive Axle Assembly 40-20-52...1481
Axle Housing/Drive Axle Disassembly 40-20-13...1481
Axle Housing/Drive Axle Parts Identification 40-20-12...1481
Brake Group Assembly 40-20-42...1481
Brake Group Disassembly 40-20-18...1481
Brake Group Inspection 40-20-24...1481
Brake Group Parts Identification 40-20-18...1481
Differential Assembly 40-20-39...1481
Differential Disassembly 40-20-25...1481
Differential Inspection 40-20-28...1481
Differential Parts Identification 40-20-25...1481
General Information 40-20-1...1481
Pinion Group Assembly 40-20-33...1481
Pinion Group Disassembly 40-20-30...1481
Pinion Group Inspection 40-20-32...1481
Pinion Group Parts Identification 40-20-29...1481
Planetary Carrier Assembly 40-20-62...1481
Planetary Carrier Disassembly 40-20-2...1481
Planetary Carrier Inspection 40-20-4...1481
Planetary Carrier Parts Identification 40-20-1...1481
Steering Knuckle Assembly 40-20-57...1481
Steering Knuckle Disassembly 40-20-10...1481
Steering Knuckle Parts Identification 40-20-9...1481
Wheel Hub Assembly 40-20-60...1481
Wheel Hub Disassembly 40-20-6...1481
Wheel Hub Inspection 40-20-9...1481
Wheel Hub Parts Identification 40-20-5...1481
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/ N 362912001 and Above) 40-22-1...1481
General Information 40-22-1...1481
Planetary carrier Assembly 40-22-53...1481
Planetary Carrier Disassembly 40-22-2...1481
Planetary Carrier Parts Identification 40-22-1...1481
Steering Knuckle and Drive Axle Parts Identification 40-22-7...1481
Steering Knuckle Assembly 40-22-50...1481
Steering Knuckle Disassembly 40-22-8...1481
Bevel pinion Parts Identification 40-22-23...1481
Bevel Pinion Assembly 40-22-27...1481
Bevel Pinion Disassembly 40-22-24...1481
Continued On Next Page...1481
DRIVE SYSTEM (Cont’d)...1482
Brake system Identification 40-22-12...1482
Brake System Assembly 40-22-41...1482
Brake System Disassembly 40-22-13...1482
Differential Parts Identification 40-22-17...1482
Differential assembly 40-22-36...1482
Differential Disassembly 40-22-18...1482
Drive Axle Disassembly 40-22-10...1482
Drive Axle Assembly 40-22-48...1482
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/ N 362911001 - 362912000) (Cont'd) 40-21-1...1482
Axle Housing/Drive Axle Assembly 40-21-46...1482
Axle Housing/Drive Axle Disassembly 40-21-13...1482
Axle Housing/Drive Axle Parts Identification 40-21-12...1482
Differential Assembly 40-21-35...1482
Differential Disassembly 40-21-16...1482
Differential Inspection 40-21-23...1482
Differential Parts Identification 40-21-16...1482
General Information 40-21-1...1482
Pinion Group Assembly 40-21-29...1482
Pinion Group Disassembly 40-21-25...1482
Pinion Group Inspection 40-21-28...1482
Pinion Group Parts Identification 40-21-24...1482
Planetary Carrier Assembly 40-21-54...1482
Planetary Carrier Disassembly 40-21-2...1482
Planetary Carrier Inspection 40-21-4...1482
Planetary Carrier Parts Identification 40-21-1...1482
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) 40-23-1...1482
Bevel pinion Assembly 40-23-18...1482
Bevel pinion Disassembly 40-23-15...1482
Differential assembly 40-23-26...1482
Differential and Bevel Pinion Parts Identification 40-23-10...1482
Differential Disassembly 40-23-11...1482
General Information 40-23-1...1482
Steering Knuckle Assembly 40-23-31...1482
Steering Knuckle Disassembly 40-23-8...1482
Steering Knuckle and Drive Axle Parts Identification 40-23-7...1482
Planetary Carrier Assembly 40-23-34...1482
Planetary Carrier Parts Identification 40-23-1...1482
Continued On Next Page...1482
DRIVE SYSTEM (Cont’d)...1483
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/ N 362911001 - 362912000) (Cont'd) 40-21-1...1483
Steering Knuckle Assembly 40-21-49...1483
Steering Knuckle Disassembly 40-21-10...1483
Steering Knuckle Parts Identification 40-21-9...1483
Wheel Hub Assembly 40-21-52...1483
Wheel Hub Disassembly 40-21-6...1483
Wheel Hub Inspection 40-21-9...1483
Wheel Hub Parts Identification 40-21-5...1483
AXLE PIVOT FRAME (Only For S/N 362811001 - 362812000, S/N 362911001 - 362912000) 40-32-1...1483
Bushing Removal And Installation 40-32-2...1483
Removal And Installation 40-32-1...1483
AXLE TOE-IN (For S/N 362812001 and Above, S/N 362912001 and Above) 40-41-1...1483
Adjustment 40-41-1...1483
AXLE TOE-IN (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) 40-40-1...1483
Adjustment 40-40-1...1483
DRIVESHAFT 40-70-1...1483
Removal And Installation 40-70-1...1483
FRONT AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) 40-33-1...1483
Installation 40-33-8...1483
Removal 40-33-1...1483
FRONT AXLE WITHOUT FRAME LEVELING (For S/N 362811001 - 362812000) 40-30-1...1483
Installation 40-30-7...1483
Removal 40-30-1...1483
FRONT AXLE WITH FRAME LEVELING (For S/N 362911001 - 362912000) 40-31-1...1483
Installation 40-31-6...1483
Removal 40-31-1...1483
PARKING BRAKE (For S/N 362812001 and Above, S/N 362912001 and Above) 40-51-1...1483
Preparing for towing 40-51-1...1483
Disengaging the hydrostatic transmission 40-51-1...1483
Releasing the parking brake 40-51-2...1483
Towing the Telescopic Handler 40-51-2...1483
Continued On Next Page...1483
DRIVE SYSTEM (Cont’d)...1484
PARKING BRAKE (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) 40-50-1...1484
Preparing for towing 40-50-1...1484
Disengaging the hydrostatic transmission 40-50-1...1484
Releasing the parking brake 40-50-2...1484
Towing the Telescopic Handler 40-50-2...1484
REAR AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) 40-91-1...1484
Installation 40-91-4...1484
Removal 40-91-1...1484
REAR AXLE (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) 40-90-1...1484
Installation 40-90-4...1484
Removal 40-90-1...1484
SERVICE BRAKE (For S/N 362812001 and Above, S/N 362912001 and Above) 40-81-1...1484
Bleeding The Brake Circuit 40-81-1...1484
Description 40-81-1...1484
SERVICE BRAKE (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) 40-80-1...1484
Bleeding The Brake Circuit 40-80-1...1484
Description 40-80-1...1484
STEERING ANGLE ADJUSTMENT (For S/N 362812001 and Above, S/N 362912001 and Above) 40-61-1...1484
Adjustment 40-61-1...1484
STEERING ANGLE ADJUSTMENT (For S/N 362811001 - 362812000, S/ N 362911001 - 362912000) 40-60-1...1484
Adjustment 40-60-1...1484
TROUBLESHOOTING 40-10-1...1484
Chart 40-10-1...1484
TROUBLESHOOTING...1485
Chart...1485
The following Troubleshooting Chart is provided for assistance in locating and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only...1485
Pinion or Ring gear tooth broken...1485
1, 2, 3, 4, 5, 6...1485
Pinion teeth pitted...1485
5, 11...1485
Axle housing bent...1485
12, 13...1485
Worn or pitted bearings...1485
3, 5, 6, 8, 11, 14...1485
Oil leakage...1485
6, 9, 10, 14, 15...1485
Excessive wear on input shaft splines...1485
3, 16, 17, 19...1485
Pinion teeth fatigue...1485
7, 12, 17, 19...1485
Side gear spline worn...1485
17, 19...1485
Thrust washer surface worn...1485
5, 6, 7...1485
Inner diameter of tapered roller bearing worn...1485
5, 6, 18, 19...1485
Bent or broken half shaft...1485
19...1485
Half shaft broken at wheel side...1485
20, 21...1485
1. Excessive gear load...1485
2. Incorrect gear adjustment (excessive play)...1485
3. Pinion nut loose...1485
4. Incorrect gear adjustment (insufficient play)...1485
5. Insufficient lubrication...1485
6. Contaminated oil...1485
7. Incorrect lubrication...1485
8. Worn bearings...1485
9. Operation at high temperature...1485
10. Low oil level...1485
11. Excessive use...1485
12. Overloaded...1485
13. Accident...1485
14. Normal Wear...1485
15. Lip seal damaged...1485
16. Pinion axle play...1485
17. Continuous overload...1485
18. Excessive pinion axle play...1485
19. Vehicle intensively operated or overloaded...1485
20. Wheel loose...1485
21. Beam housing bent...1485
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...1487
Planetary Carrier Parts Identification...1487
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1488
Figure 40-20-1...1488
Figure 40-20-2...1488
Figure 40-20-3...1488
Figure 40-20-4...1488
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1489
Figure 40-20-5...1489
Figure 40-20-6...1489
Figure 40-20-7...1489
Figure 40-20-8...1489
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1490
Figure 40-20-9...1490
Figure 40-20-10...1490
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1491
Wheel Hub Parts Identification...1491
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1492
Figure 40-20-11...1492
Figure 40-20-12...1492
Figure 40-20-13...1492
Figure 40-20-14...1492
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1493
Figure 40-20-15...1493
Figure 40-20-16...1493
Figure 40-20-17...1493
Figure 40-20-18...1493
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1494
Figure 40-20-19...1494
Figure 40-20-20...1494
Figure 40-20-21...1494
Figure 40-20-22...1494
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1495
Figure 40-20-23...1495
Steering Knuckle Parts Identification...1495
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1496
Figure 40-20-24...1496
Figure 40-20-25...1496
Figure 40-20-26...1496
Figure 40-20-27...1496
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1497
Figure 40-20-28...1497
Figure 40-20-29...1497
Figure 40-20-30...1497
Figure 40-20-31...1497
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1498
Figure 40-20-32...1498
Figure 40-20-33...1498
Axle Housing/Drive Axle Parts Identification...1498
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1499
Figure 40-20-34...1499
Figure 40-20-35...1499
Figure 40-20-36...1499
Figure 40-20-37...1499
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1500
Figure 40-20-38...1500
Figure 40-20-39...1500
Figure 40-20-40...1500
Figure 40-20-41...1500
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1501
Figure 40-20-42...1501
Figure 40-20-43...1501
Figure 40-20-44...1501
Figure 40-20-45...1501
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1502
Figure 40-20-46...1502
Figure 40-20-47...1502
Figure 40-20-48...1502
Figure 40-20-49...1502
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1503
Figure 40-20-50...1503
Figure 40-20-51...1503
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1504
Brake Group Parts Identification...1504
Figure 40-20-52...1504
Figure 40-20-53...1504
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1505
Figure 40-20-54...1505
Figure 40-20-55...1505
Figure 40-20-56...1505
Figure 40-20-57...1505
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1506
Figure 40-20-58...1506
Figure 40-20-59...1506
Figure 40-20-60...1506
Figure 40-20-61...1506
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1507
Figure 40-20-62...1507
Figure 40-20-63...1507
Figure 40-20-64...1507
Figure 40-20-65...1507
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1508
Figure 40-20-66...1508
Figure 40-20-67...1508
Figure 40-20-68...1508
Figure 40-20-69...1508
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1509
Figure 40-20-70...1509
Figure 40-20-71...1509
Figure 40-20-72...1509
Figure 40-20-73...1509
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1510
Figure 40-20-74...1510
Figure 40-20-75...1510
Figure 40-20-76...1510
Figure 40-20-77...1510
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1511
Differential Parts Identification...1511
Figure 40-20-78...1511
Figure 40-20-79...1511
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1512
Figure 40-20-80...1512
Figure 40-20-81...1512
Figure 40-20-82...1512
Figure 40-20-83...1512
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1513
Figure 40-20-84...1513
Figure 40-20-85...1513
Figure 40-20-86...1513
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1514
Figure 40-20-87...1514
Figure 40-20-88...1514
Figure 40-20-89...1514
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1515
Pinion Group Parts Identification...1515
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1516
Figure 40-20-90...1516
Figure 40-20-91...1516
Figure 40-20-92...1516
Figure 40-20-93...1516
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1517
Figure 40-20-94...1517
Figure 40-20-95...1517
Figure 40-20-96...1517
Figure 40-20-97...1517
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1518
Figure 40-20-98...1518
Figure 40-20-99...1518
Figure 40-20-100...1518
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1519
Figure 40-20-101...1519
Figure 40-20-102...1519
Figure 40-20-103...1519
Figure 40-20-104...1519
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1520
Figure 40-20-105...1520
Figure 40-20-106...1520
Figure 40-20-107...1520
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1521
Figure 40-20-108...1521
Figure 40-20-109...1521
Figure 40-20-110...1521
Figure 40-20-111...1521
2.5...1521
2.6...1521
2.7...1521
2.8...1521
2.9...1521
3.0...1521
3.1...1521
3.2...1521
3.3...1521
3.4...1521
Qty...1521
-...1521
-...1521
-...1521
-...1521
-...1521
-...1521
-...1521
-...1521
-...1521
-...1521
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1522
Figure 40-20-112...1522
Figure 40-20-113...1522
Figure 40-20-114...1522
Figure 40-20-115...1522
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1523
Figure 40-20-116...1523
Figure 40-20-117...1523
Figure 40-20-118...1523
Figure 40-20-119...1523
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1524
Figure 40-20-120...1524
Figure 40-20-121...1524
Figure 40-20-122...1524
Figure 40-20-123...1524
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1525
Figure 40-20-124...1525
Figure 40-20-125...1525
Figure 40-20-126...1525
Figure 40-20-127...1525
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1526
Figure 40-20-128...1526
Figure 40-20-129...1526
Figure 40-20-130...1526
Figure 40-20-131...1526
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1527
Figure 40-20-132...1527
Figure 40-20-133...1527
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1528
Figure 40-20-134...1528
Figure 40-20-135...1528
Figure 40-20-136...1528
Figure 40-20-137...1528
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1529
Figure 40-20-138...1529
Figure 40-20-139...1529
Figure 40-20-140...1529
Figure 40-20-141...1529
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1530
Figure 40-20-142...1530
Figure 40-20-143...1530
Figure 40-20-144...1530
Figure 40-20-145...1530
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1531
Figure 40-20-146...1531
Figure 40-20-147...1531
Figure 40-20-148...1531
Figure 40-20-149...1531
AXLE AND DIFFERENTIAL (FRONT) (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1532
Figure 40-20-150...1532
Figure 40-20-151...1532
Figure 40-20-152...1532
Figure 40-20-153...1532
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1533
Figure 40-20-154...1533
Figure 40-20-155...1533
Figure 40-20-156...1533
Figure 40-20-157...1533
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1534
Figure 40-20-158...1534
Figure 40-20-159...1534
Figure 40-20-160...1534
Figure 40-20-161...1534
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1535
Figure 40-20-162...1535
Figure 40-20-163...1535
Figure 40-20-164...1535
Figure 40-20-165...1535
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1536
Figure 40-20-166...1536
Figure 40-20-167...1536
Figure 40-20-168...1536
Figure 40-20-169...1536
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1537
Figure 40-20-170...1537
Figure 40-20-171...1537
Figure 40-20-172...1537
Figure 40-20-173...1537
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1538
Figure 40-20-174...1538
Figure 40-20-175...1538
Figure 40-20-176...1538
Figure 40-20-177...1538
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1539
Figure 40-20-178...1539
Figure 40-20-179...1539
Figure 40-20-180...1539
Figure 40-20-181...1539
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1540
Figure 40-20-182...1540
Figure 40-20-183...1540
Figure 40-20-184...1540
Figure 40-20-185...1540
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1541
Figure 40-20-186...1541
Figure 40-20-187...1541
Figure 40-20-188...1541
Figure 40-20-189...1541
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1542
Figure 40-20-190...1542
Figure 40-20-191...1542
Figure 40-20-192...1542
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1543
Figure 40-20-193...1543
Figure 40-20-194...1543
Figure 40-20-195...1543
Figure 40-20-196...1543
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1544
Figure 40-20-197...1544
Figure 40-20-198...1544
Figure 40-20-199...1544
Figure 40-20-200...1544
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1545
Figure 40-20-201...1545
Figure 40-20-202...1545
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1546
Figure 40-20-203...1546
Figure 40-20-204...1546
Figure 40-20-205...1546
Figure 40-20-206...1546
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1547
Figure 40-20-207...1547
Figure 40-20-208...1547
Figure 40-20-209...1547
Figure 40-20-210...1547
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1548
Figure 40-20-211...1548
Figure 40-20-212...1548
Figure 40-20-213...1548
Figure 40-20-214...1548
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1549
Figure 40-20-215...1549
Figure 40-20-216...1549
Figure 40-20-217...1549
Figure 40-20-218...1549
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1551
Planetary Carrier Parts Identification...1551
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1552
Figure 40-21-1...1552
Figure 40-21-2...1552
Figure 40-21-3...1552
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1553
Figure 40-21-4...1553
Figure 40-21-5...1553
Figure 40-21-6...1553
Figure 40-21-7...1553
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1554
Figure 40-21-8...1554
Figure 40-21-9...1554
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1555
Wheel Hub Parts Identification...1555
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1556
Figure 40-21-10...1556
Figure 40-21-11...1556
Figure 40-21-12...1556
Figure 40-21-13...1556
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1557
Figure 40-21-14...1557
Figure 40-21-15...1557
Figure 40-21-16...1557
Figure 40-21-17...1557
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1558
Figure 40-21-18...1558
Figure 40-21-19...1558
Figure 40-21-20...1558
Figure 40-21-21...1558
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1559
Figure 40-21-22...1559
Steering Knuckle Parts Identification...1559
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1560
Figure 40-21-23...1560
Figure 40-21-24...1560
Figure 40-21-25...1560
Figure 40-21-26...1560
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1561
Figure 40-21-27...1561
Figure 40-21-28...1561
Figure 40-21-29...1561
Figure 40-21-30...1561
Figure 40-21-31...1561
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1562
Figure 40-21-32...1562
Figure 40-21-33...1562
Axle Housing/Drive Axle Parts Identification...1562
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1563
Figure 40-21-34...1563
Figure 40-21-35...1563
Figure 40-21-36...1563
Figure 40-21-37...1563
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1564
Figure 40-21-38...1564
Figure 40-21-39...1564
Figure 40-21-40...1564
Figure 40-21-41...1564
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1565
Figure 40-21-42...1565
Figure 40-21-43...1565
Figure 40-21-44...1565
Figure 40-21-45...1565
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1566
Differential Parts Identification...1566
Figure 40-21-46...1566
Figure 40-21-47...1566
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1567
Figure 40-21-48...1567
Figure 40-21-49...1567
Figure 40-21-50...1567
Figure 40-21-51...1567
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1568
Figure 40-21-52...1568
Figure 40-21-53...1568
Figure 40-21-54...1568
Figure 40-21-55...1568
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1569
Figure 40-21-56...1569
Figure 40-21-57...1569
Figure 40-21-58...1569
Figure 40-21-59...1569
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1570
Figure 40-21-60...1570
Figure 40-21-61...1570
Figure 40-21-62...1570
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1571
Figure 40-21-63...1571
Figure 40-21-64...1571
Figure 40-21-65...1571
Figure 40-21-66...1571
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1572
Figure 40-21-67...1572
Figure 40-21-68...1572
Figure 40-21-69...1572
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1573
Figure 40-21-70...1573
Figure 40-21-71...1573
Figure 40-21-72...1573
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1574
Pinion Group Parts Identification...1574
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1575
Figure 40-21-73...1575
Figure 40-21-74...1575
Figure 40-21-75...1575
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1576
Figure 40-21-76...1576
Figure 40-21-77...1576
Figure 40-21-78...1576
Figure 40-21-79...1576
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1577
Figure 40-21-80...1577
Figure 40-21-81...1577
Figure 40-21-82...1577
Figure 40-21-83...1577
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1578
Figure 40-21-84...1578
Figure 40-21-85...1578
Figure 40-21-86...1578
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1579
Figure 40-21-87...1579
Figure 40-21-88...1579
Figure 40-21-89...1579
Figure 40-21-90...1579
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1580
Figure 40-21-91...1580
Figure 40-21-92...1580
Figure 40-21-93...1580
Figure 40-21-94...1580
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1581
Figure 40-21-95...1581
Figure 40-21-96...1581
2.5...1581
2.6...1581
2.7...1581
2.8...1581
2.9...1581
3.0...1581
3.1...1581
3.2...1581
3.3...1581
3.4...1581
Qty...1581
-...1581
-...1581
-...1581
-...1581
-...1581
-...1581
-...1581
-...1581
-...1581
-...1581
Figure 40-21-97...1581
Figure 40-21-98...1581
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1582
Figure 40-21-99...1582
Figure 40-21-100...1582
Figure 40-21-101...1582
Figure 40-21-102...1582
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1583
Figure 40-21-103...1583
Figure 40-21-104...1583
Figure 40-21-105...1583
Figure 40-21-106...1583
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1584
Figure 40-21-107...1584
Figure 40-21-108...1584
Figure 40-21-109...1584
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1585
Figure 40-21-110...1585
Figure 40-21-111...1585
Figure 40-21-112...1585
Figure 40-21-113...1585
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1586
Figure 40-21-114...1586
Figure 40-21-115...1586
Figure 40-21-116...1586
Figure 40-21-117...1586
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1587
Figure 40-21-118...1587
Figure 40-21-119...1587
Figure 40-21-120...1587
Figure 40-21-121...1587
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1588
Figure 40-21-122...1588
Figure 40-21-123...1588
Figure 40-21-124...1588
Figure 40-21-125...1588
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1589
Figure 40-21-126...1589
Figure 40-21-127...1589
Figure 40-21-128...1589
Figure 40-21-129...1589
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1590
Figure 40-21-130...1590
Figure 40-21-131...1590
Figure 40-21-132...1590
Figure 40-21-133...1590
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1591
Figure 40-21-134...1591
Figure 40-21-135...1591
Figure 40-21-136...1591
Figure 40-21-137...1591
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1592
Figure 40-21-138...1592
Figure 40-21-139...1592
Figure 40-21-140...1592
Figure 40-21-141...1592
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1593
Figure 40-21-142...1593
Figure 40-21-143...1593
Figure 40-21-144...1593
Figure 40-21-145...1593
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1594
Figure 40-21-146...1594
Figure 40-21-147...1594
Figure 40-21-148...1594
Figure 40-21-149...1594
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1595
Figure 40-21-150...1595
Figure 40-21-151...1595
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1596
Figure 40-21-152...1596
Figure 40-21-153...1596
Figure 40-21-154...1596
Figure 40-21-155...1596
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1597
Figure 40-21-156...1597
Figure 40-21-157...1597
Figure 40-21-158...1597
Figure 40-21-159...1597
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1598
Figure 40-21-160...1598
Figure 40-21-161...1598
Figure 40-21-162...1598
Figure 40-21-163...1598
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1599
Figure 40-21-164...1599
Figure 40-21-165...1599
Figure 40-21-166...1599
Figure 40-21-167...1599
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1600
Figure 40-21-168...1600
Figure 40-21-169...1600
Figure 40-21-170...1600
Figure 40-21-171...1600
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1601
Figure 40-21-172...1601
Figure 40-21-173...1601
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1602
Figure 40-21-174...1602
Figure 40-21-175...1602
Figure 40-21-176...1602
Figure 40-21-177...1602
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1603
Figure 40-21-178...1603
Figure 40-21-179...1603
Figure 40-21-180...1603
Figure 40-21-181...1603
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1604
Figure 40-21-182...1604
Figure 40-21-183...1604
Figure 40-21-184...1604
Figure 40-21-185...1604
AXLE AND DIFFERENTIAL (REAR) (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (Cont'd)...1605
Figure 40-21-186...1605
Figure 40-21-187...1605
Figure 40-21-188...1605
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above)...1607
General Information...1607
Planetary Carrier Parts Identification...1607
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1608
Planetary Carrier Disassembly...1608
Figure 40-22-1...1608
Figure 40-40-22-2...1608
Figure 40-22-3...1608
Figure 40-22-4...1608
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1609
Figure 40-22-5...1609
Figure 40-22-6...1609
Figure 40-22-7...1609
Figure 40-22-8...1609
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1610
Figure 40-22-9...1610
Figure 40-22-10...1610
Figure 40-22-11...1610
Figure 40-22-12...1610
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1611
Figure 40-22-13...1611
Figure 40-22-14...1611
Figure 40-22-15...1611
Figure 40-22-16...1611
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1612
Figure 40-22-17...1612
Steering Knuckle and Drive Axle Parts Identification...1613
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1614
Steering Knuckle Disassembly...1614
Figure 40-22-18...1614
Figure 40-22-19...1614
Figure 40-22-20...1614
Figure 40-22-21...1614
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1615
Figure 40-22-22...1615
Figure 40-22-23...1615
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1616
Drive Axle Disassembly...1616
Figure 40-22-24...1616
Figure 40-22-25...1616
Figure 40-22-26...1616
Figure 40-22-27...1616
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1617
Figure 40-22-28...1617
Figure 40-22-29...1617
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1618
Brake system Identification...1618
Figure 40-22-30...1618
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1619
Brake System Disassembly...1619
Figure 40-22-31...1619
Figure 40-22-32...1619
Figure 40-22-33...1619
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1620
Figure 40-22-34...1620
Figure 40-22-35...1620
Figure 40-22-36...1620
Figure 40-22-37...1620
Figure 40-22-38...1620
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1621
Figure 40-22-39...1621
Figure 40-22-40...1621
Figure 40-22-41...1621
Figure 40-22-42...1621
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1622
Figure 40-22-43...1622
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1623
Differential Parts Identification...1623
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1624
Differential Disassembly...1624
Figure 40-22-44...1624
Figure 40-22-45...1624
Figure 40-22-46...1624
Figure 40-22-47...1624
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1625
Figure 40-22-48...1625
Figure 40-22-49...1625
Figure 40-22-50...1625
Figure 40-22-51...1625
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1626
Figure 40-22-52...1626
Figure 40-22-53...1626
Figure 40-22-54...1626
Figure 40-22-55...1626
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1627
Figure 40-22-56...1627
Figure 40-22-57...1627
Figure 40-22-58...1627
Figure 40-22-59...1627
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1628
Figure 40-22-60...1628
Figure 40-22-61...1628
Figure 40-22-62...1628
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1629
Bevel pinion Parts Identification...1629
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1630
Bevel Pinion Disassembly...1630
Figure 40-22-63...1630
Figure 40-22-64...1630
Figure 40-22-65...1630
Figure 40-22-66...1630
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1631
Figure 40-22-67...1631
Figure 40-22-68...1631
Figure 40-22-69...1631
Figure 40-22-70...1631
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1632
Figure 40-22-71...1632
Figure 40-22-72...1632
Figure 40-22-73...1632
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1633
Bevel Pinion Assembly...1633
Figure 40-22-74...1633
Figure 40-22-75...1633
Figure 40-22-76...1633
Figure 40-22-77...1633
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1634
Figure 40-22-78...1634
Figure 40-22-79...1634
Figure 40-22-80...1634
Figure 40-22-81...1634
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1635
Figure 40-22-82...1635
Figure 40-22-83...1635
Figure 40-22-84...1635
Figure 40-22-85...1635
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1636
Figure 40-22-86...1636
Figure 40-22-87...1636
Figure 40-22-88...1636
Figure 40-22-89...1636
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1637
Figure 40-22-90...1637
Figure 40-22-91...1637
Figure 40-22-92...1637
Figure 40-22-93...1637
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1638
Figure 40-22-94...1638
Figure 40-22-95...1638
Figure 40-22-96...1638
Figure 40-22-97...1638
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1639
Figure 40-22-98...1639
Figure 40-22-99...1639
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1640
Figure 40-22-100...1640
Figure 40-22-101...1640
Figure 40-22-102...1640
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1641
Figure 40-22-103...1641
Figure 40-22-104...1641
Figure 40-22-105...1641
Figure 40-22-106...1641
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1642
Differential assembly...1642
Figure 40-22-107...1642
Figure 40-22-108...1642
Figure 40-22-109...1642
Figure 40-22-110...1642
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1643
Figure 40-22-111...1643
Figure 40-22-112...1643
Figure 40-22-113...1643
Figure 40-22-114...1643
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1644
Figure 40-22-115...1644
Figure 40-22-116...1644
Figure 40-22-117...1644
Figure 40-22-118...1644
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1645
Figure 40-22-119...1645
Setting Ring And Pinion Backlash...1645
Figure 40-22-120...1645
Figure 40-22-121...1645
Figure 40-22-122...1645
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1646
Figure 40-22-123...1646
Figure 40-22-124...1646
14-32...1646
0.18...1646
0.23...1646
Figure 40-22-125...1646
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1647
Brake System Assembly...1647
Figure 40-22-126...1647
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1648
Figure 40-22-127...1648
Figure 40-22-128...1648
Figure 40-22-129...1648
Figure 40-22-130...1648
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1649
Figure 40-22-131...1649
Figure 40-22-132...1649
Figure 40-22-133...1649
Figure 40-22-134...1649
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1650
Figure 40-22-135...1650
Figure 40-22-136...1650
Figure 40-22-137...1650
Figure 40-22-138...1650
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1651
Figure 40-22-139...1651
Figure 40-22-140...1651
Figure 40-22-141...1651
Figure 40-22-142...1651
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1652
Figure 40-22-143...1652
Figure 40-22-144...1652
Figure 40-22-145...1652
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1653
Figure 40-22-146...1653
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1654
Drive Axle Assembly...1654
Figure 40-22-147...1654
Figure 40-22-148...1654
Figure 40-22-149...1654
Figure 40-22-150...1654
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1655
Figure 40-22-151...1655
Figure 40-22-152...1655
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1656
Steering Knuckle Assembly...1656
Figure 40-22-153...1656
Figure 40-22-154...1656
Figure 40-22-155...1656
Figure 40-22-156...1656
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1657
Figure 40-22-157...1657
Figure 40-22-158...1657
Figure 40-22-159...1657
Figure 40-22-160...1657
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1658
Figure 40-22-161...1658
Figure 40-22-162...1658
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1659
Planetary carrier Assembly...1659
Figure 40-22-163...1659
Figure 40-22-164...1659
Figure 40-22-165...1659
Figure 40-22-166...1659
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1660
Figure 40-22-167...1660
Figure 40-22-168...1660
Figure 40-22-169...1660
Figure 40-22-170...1660
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1661
Figure 40-22-171...1661
Figure 40-22-172...1661
Figure 40-22-173...1661
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1662
Figure 40-22-174...1662
Figure 40-22-175...1662
Figure 40-22-176...1662
Figure 40-22-177...1662
AXLE AND DIFFERENTIAL (FRONT) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1663
Figure 40-22-178...1663
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above)...1665
General Information...1665
Planetary Carrier Parts Identification...1665
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1666
Figure 40-23-1...1666
Figure 40-23-2...1666
Figure 40-23-3...1666
Figure 40-23-4...1666
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1667
Figure 40-23-5...1667
Figure 40-23-6...1667
Figure 40-23-7...1667
Figure 40-23-8...1667
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1668
Figure 40-23-9...1668
Figure 40-23-10...1668
Figure 40-23-11...1668
Figure 40-23-12...1668
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1669
Figure 40-23-13...1669
Figure 40-23-14...1669
Figure 40-23-15...1669
Figure 40-23-16...1669
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1670
Figure 40-23-17...1670
Steering Knuckle and Drive Axle Parts Identification...1671
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1672
Steering Knuckle Disassembly...1672
Figure 40-23-18...1672
Figure 40-23-19...1672
Figure 40-23-20...1672
Figure 40-23-21...1672
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1673
Figure 40-23-22...1673
Figure 40-23-23...1673
Figure 40-23-24...1673
Differential and Bevel Pinion Parts Identification...1674
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1675
Differential Disassembly...1675
Figure 40-23-25...1675
Figure 40-23-26...1675
Figure 40-23-27...1675
Figure 40-23-28...1675
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1676
Figure 40-23-29...1676
Figure 40-23-30...1676
Figure 40-23-31...1676
Figure 40-23-32...1676
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1677
Figure 40-23-33...1677
Figure 40-23-34...1677
Figure 40-23-35...1677
Figure 40-23-36...1677
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1678
Figure 40-23-37...1678
Figure 40-23-38...1678
Figure 40-23-39...1678
Figure 40-23-40...1678
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1679
Bevel pinion Disassembly...1679
Figure 40-23-41...1679
Figure 40-23-42...1679
Figure 40-23-43...1679
Figure 40-23-44...1679
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1680
Figure 40-23-45...1680
Figure 40-23-46...1680
Figure 40-23-47...1680
Figure 40-23-48...1680
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1681
Figure 40-23-49...1681
Figure 40-23-50...1681
Figure 40-23-51...1681
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1682
Bevel pinion Assembly...1682
Figure 40-23-52...1682
Figure 40-23-53...1682
Figure 40-23-54...1682
Figure 40-23-55...1682
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1683
Figure 40-23-56...1683
Figure 40-23-57...1683
Figure 40-23-58...1683
Figure 40-23-59...1683
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1684
Figure 40-23-60...1684
Figure 40-23-61...1684
Figure 40-23-62...1684
Figure 40-23-63...1684
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1685
Figure 40-23-64...1685
Figure 40-23-65...1685
Figure 40-23-66...1685
Figure 40-23-67...1685
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1686
Figure 40-23-68...1686
Figure 40-23-69...1686
Figure 40-23-70...1686
Figure 40-23-71...1686
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1687
Figure 40-23-72...1687
Figure 40-23-73...1687
Figure 40-23-74...1687
Figure 40-23-75...1687
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1688
Figure 40-23-76...1688
Figure 40-23-77...1688
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1689
Figure 40-23-78...1689
Figure 40-23-79...1689
Figure 40-23-80...1689
Figure 40-23-81...1689
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1690
Differential assembly...1690
Figure 40-23-82...1690
Figure 40-23-83...1690
Figure 40-23-84...1690
Figure 40-23-85...1690
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1691
Figure 40-23-86...1691
Figure 40-23-87...1691
Figure 40-23-88...1691
Figure 40-23-89...1691
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1692
Figure 40-23-90...1692
Figure 40-23-91...1692
Figure 40-23-92...1692
Figure 40-23-93...1692
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1693
Figure 40-23-94...1693
Figure 40-23-95...1693
Figure 40-23-96...1693
Figure 40-23-97...1693
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1694
Figure 40-23-98...1694
Figure 40-23-99...1694
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1695
Steering Knuckle Assembly...1695
Figure 40-23-100...1695
Figure 40-23-101...1695
Figure 40-23-102...1695
Figure 40-23-103...1695
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1696
Figure 40-23-104...1696
Figure 40-23-105...1696
Figure 40-23-106...1696
Figure 40-23-107...1696
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1697
Figure 40-23-108...1697
Figure 40-23-109...1697
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1698
Planetary Carrier Assembly...1698
Figure 40-23-110...1698
Figure 40-23-111...1698
Figure 40-23-112...1698
Figure 40-23-113...1698
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1699
Figure 40-23-114...1699
Figure 40-23-115...1699
Figure 40-23-116...1699
Figure 40-23-117...1699
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1700
Figure 40-23-118...1700
Figure 40-23-119...1700
Figure 40-23-120...1700
Figure 40-23-121...1700
AXLE AND DIFFERENTIAL (REAR) (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1701
Figure 40-23-122...1701
Figure 40-23-123...1701
Figure 40-23-124...1701
Special tools...1702
FRONT AXLE WITHOUT FRAME LEVELING (For S/N 362811001 - 362812000)...1703
Figure 40-30-1...1703
Figure 40-30-2...1703
Figure 40-30-3...1703
FRONT AXLE WITHOUT FRAME LEVELING (Cont'd)...1704
Figure 40-30-4...1704
Figure 40-30-5...1704
Figure 40-30-6...1704
Figure 40-30-7...1704
Figure 40-30-8...1704
FRONT AXLE WITHOUT FRAME LEVELING (Cont'd)...1705
Figure 40-30-9...1705
Figure 40-30-10...1705
Figure 40-30-11...1705
Figure 40-30-12...1705
FRONT AXLE WITHOUT FRAME LEVELING (Cont'd)...1706
Figure 40-30-13...1706
Figure 40-30-14...1706
Figure 40-30-15...1706
Figure 40-30-16...1706
FRONT AXLE WITHOUT FRAME LEVELING (Cont'd)...1707
Figure 40-30-17...1707
Figure 40-30-18...1707
Figure 40-30-19...1707
Figure 40-30-20...1707
FRONT AXLE WITHOUT FRAME LEVELING (Cont'd)...1708
Figure 40-30-21...1708
FRONT AXLE WITHOUT FRAME LEVELING (Cont'd)...1709
Figure 40-30-22...1709
Figure 40-30-23...1709
Figure 40-30-24...1709
Figure 40-30-25...1709
FRONT AXLE WITHOUT FRAME LEVELING (Cont'd)...1710
Figure 40-30-26...1710
Figure 40-30-27...1710
Figure 40-30-28...1710
Figure 40-30-29...1710
FRONT AXLE WITHOUT FRAME LEVELING (Cont'd)...1711
Figure 40-30-30...1711
Figure 40-30-31...1711
Figure 40-30-32...1711
Figure 40-30-33...1711
FRONT AXLE WITHOUT FRAME LEVELING (Cont'd)...1712
Figure 40-30-34...1712
Figure 40-30-35...1712
Figure 40-30-36...1712
Figure 40-30-37...1712
FRONT AXLE WITHOUT FRAME LEVELING (Cont'd)...1713
Figure 40-30-38...1713
Figure 40-30-39...1713
Figure 40-30-40...1713
Figure 40-30-41...1713
FRONT AXLE WITHOUT FRAME LEVELING (Cont'd)...1714
Figure 40-30-42...1714
FRONT AXLE WITH FRAME LEVELING (For S/N 362911001 - 362912000)...1715
Figure 40-31-1...1715
Figure 40-31-2...1715
Figure 40-31-3...1715
FRONT AXLE WITH FRAME LEVELING (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (cont’d)...1716
Figure 40-31-4...1716
Figure 40-31-5...1716
Figure 40-31-6...1716
Figure 40-31-7...1716
FRONT AXLE WITH FRAME LEVELING (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1717
Figure 40-31-8...1717
Figure 40-31-9...1717
Figure 40-31-10...1717
Figure 40-31-11...1717
FRONT AXLE WITH FRAME LEVELING (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1718
Figure 40-31-12...1718
Figure 40-31-13...1718
Figure 40-31-14...1718
Figure 40-31-15...1718
FRONT AXLE WITH FRAME LEVELING (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1719
Figure 40-31-16...1719
Figure 40-31-17...1719
Figure 40-31-18...1719
Figure 40-31-19...1719
FRONT AXLE WITH FRAME LEVELING (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1720
Figure 40-31-20...1720
Figure 40-31-21...1720
Figure 40-31-22...1720
FRONT AXLE WITH FRAME LEVELING (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1721
Figure 40-31-23...1721
Figure 40-31-24...1721
Figure 40-31-25...1721
Figure 40-31-26...1721
FRONT AXLE WITH FRAME LEVELING (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1722
Figure 40-31-27...1722
Figure 40-31-28...1722
Figure 40-31-29...1722
Figure 40-31-30...1722
FRONT AXLE WITH FRAME LEVELING (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1723
Figure 40-31-31...1723
Figure 40-31-32...1723
Figure 40-31-33...1723
Figure 40-31-34...1723
FRONT AXLE WITH FRAME LEVELING (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1724
Figure 40-31-35...1724
Figure 40-31-36...1724
Figure 40-31-37...1724
Figure 40-31-38...1724
FRONT AXLE WITH FRAME LEVELING (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1725
Figure 40-31-39...1725
Figure 40-31-40...1725
AXLE PIVOT FRAME (Only For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...1727
Figure 40-32-1...1727
Figure 40-32-2...1727
Figure 40-32-3...1727
Figure 40-32-4...1727
AXLE PIVOT FRAME (CONT’D)...1728
Figure 40-32-5...1728
FRONT AXLE (For S/N 362812001 and Above, S/N 362912001 and Above)...1729
Figure 40-33-1...1729
Figure 40-33-2...1729
Figure 40-33-3...1729
front axle (For S/N 362812001 and Above, S/N 362912001 and Above) (cont’d)...1730
Figure 40-33-4...1730
Figure 40-33-5...1730
Figure 40-33-6...1730
Figure 40-33-7...1730
FRONT AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1731
Figure 40-33-8...1731
Figure 40-33-9...1731
Figure 40-33-10...1731
Figure 40-33-11...1731
FRONT AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1732
Figure 40-33-12...1732
Figure 40-33-13...1732
Figure 40-33-14...1732
Figure 40-33-15...1732
FRONT AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1733
Figure 40-33-16...1733
Figure 40-33-17...1733
Figure 40-33-18...1733
Figure 40-33-19...1733
FRONT AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1734
Figure 40-33-20...1734
Figure 40-33-21...1734
Figure 40-33-22...1734
Figure 40-33-23...1734
FRONT AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1735
Figure 40-33-24...1735
Figure 40-33-25...1735
Figure 40-33-26...1735
Figure 40-33-27...1735
Figure 40-33-28...1736
Figure 40-33-29...1736
Figure 40-33-30...1736
Figure 40-33-31...1736
FRONT AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1737
Figure 40-33-32...1737
Figure 40-33-33...1737
Figure 40-33-34...1737
Figure 40-33-35...1737
FRONT AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1738
Figure 40-33-36...1738
Figure 40-33-37...1738
Figure 40-33-38...1738
Figure 40-33-39...1738
FRONT AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1739
Figure 40-33-40...1739
Figure 40-33-41...1739
Figure 40-33-42...1739
Figure 40-33-43...1739
FRONT AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1740
Figure 40-33-44...1740
Figure 40-33-45...1740
Figure 40-33-46...1740
Figure 40-33-47...1740
FRONT AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1741
Figure 40-33-48...1741
Figure 40-33-49...1741
Figure 40-33-50...1741
Figure 40-33-51...1741
FRONT AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1742
Figure 40-33-52...1742
Figure 40-33-53...1742
Figure 40-33-54...1742
AXLE TOE-IN (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...1743
Figure 40-40-1...1743
Figure 40-40-2...1743
Figure 40-40-3...1743
AXLE TOE-IN (For S/N 362812001 and Above, S/N 362912001 and Above)...1745
Figure 40-41-2...1745
Figure 40-41-3...1745
PARKING BRAKE (For S/N 362811001 - 362812000, S/ N 362911001 - 362912000)...1747
Figure 10-40-1...1747
Figure 10-40-2...1747
PARKING BRAKE (For S/N 3628 12000 and below, S/N 3629 12000 and below) (Cont'd)...1748
Figure 10-40-3...1748
Figure 10-40-4...1748
PARKING BRAKE (For S/N 362812001 and Above, S/ N 362912001 and Above)...1749
Figure 10-40-5...1749
Figure 10-40-6...1749
PARKING BRAKE (For S/N 3628 12000 and below, S/N 3629 12000 and below) (Cont'd)...1750
Figure 10-40-7...1750
Figure 10-40-8...1750
STEERING ANGLE ADJUSTMENT (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...1751
Figure 40-60-1...1751
Figure 40-60-2...1751
Figure 40-60-3...1751
Figure 40-60-4...1751
STEERING ANGLE ADJUSTMENT (For S/N 362812001 and Above, S/N 362912001 and Above)...1753
Figure 40-61-2...1753
Figure 40-61-3...1753
Figure 40-61-4...1753
DRIVESHAFT...1755
Figure 40-70-2...1755
Figure 40-70-2...1755
SERVICE BRAKE (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...1757
Figure 40-80-1...1757
Figure 40-80-2...1757
Figure 40-80-3...1757
SERVICE BRAKE (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1758
Figure 40-80-4...1758
Figure 40-80-5...1758
SERVICE BRAKE (For S/N 362812001 and Above, S/N 362912001 and Above)...1759
Figure 40-81-1...1759
Figure 40-81-2...1759
SERVICE BRAKE (For S/N 362812001 and Above, S/N 362912001 and Above) (Cont’d)...1760
Figure 40-81-3...1760
Figure 40-81-4...1760
REAR AXLE (For S/N 362811001 - 362812000, S/N 362911001 - 362912000)...1761
Figure 40-90-1...1761
Figure 40-90-2...1761
Figure 40-90-3...1761
REAR AXLE (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1762
Figure 40-90-4...1762
Figure 40-90-5...1762
Figure 40-90-6...1762
Figure 40-90-7...1762
REAR AXLE (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1763
Figure 40-90-8...1763
Figure 40-90-9...1763
Figure 40-90-10...1763
Figure 40-90-11...1763
REAR AXLE (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1764
Figure 40-90-12...1764
Figure 40-90-13...1764
Figure 40-90-14...1764
Figure 40-90-15...1764
REAR AXLE (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1765
Figure 40-90-16...1765
Figure 40-90-17...1765
Figure 40-90-18...1765
Figure 40-90-19...1765
REAR AXLE(For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1766
Figure 40-90-20...1766
Figure 40-90-21...1766
Figure 40-90-22...1766
Figure 40-90-23...1766
REAR AXLE (For S/N 362811001 - 362812000, S/N 362911001 - 362912000) (CONT’D)...1767
Figure 40-90-24...1767
Figure 40-90-25...1767
REAR AXLE (For S/N 362812001 and Above, S/N 362912001 and Above)...1769
Figure 40-91-2...1769
Figure 40-91-3...1769
REAR AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1770
Figure 40-91-4...1770
Figure 40-91-5...1770
Figure 40-91-6...1770
Figure 40-91-7...1770
REAR AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1771
Figure 40-91-8...1771
Figure 40-91-9...1771
Figure 40-91-10...1771
Figure 40-91-11...1771
REAR AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1772
Figure 40-91-12...1772
Figure 40-91-13...1772
Figure 40-91-14...1772
Figure 40-91-15...1772
REAR AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1773
Figure 40-91-16...1773
Figure 40-91-17...1773
Figure 40-91-18...1773
Figure 40-91-19...1773
REAR AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) CONT’D)...1774
Figure 40-91-20...1774
Figure 40-91-21...1774
Figure 40-91-22...1774
Figure 40-91-23...1774
REAR AXLE (For S/N 362812001 and Above, S/N 362912001 and Above) (CONT’D)...1775
Figure 40-91-24...1775
Figure 40-91-25...1775
MAIN FRAME...1777
AIR INTAKE COWLING 50-71-1...1777
Removal And Installation 50-71-1...1777
BOOM ASSEMBLY 50-30-1...1777
Removal And Installation 50-30-1...1777
DASH COVER/STEERING COLUMN COVER 50-130-1...1777
Removal And Installation 50-130-1...1777
ENGINE COVER 50-70-1...1777
Gas Cylinder Removal And Installation 50-70-1...1777
Removal And Installation 50-70-1...1777
FENDER 50-110-1...1777
Removal And Installation 50-110-1...1777
FUEL TANK 50-80-1...1777
Removal And Installation 50-80-1...1777
INNER BOOM 50-40-1...1777
Installation 50-40-3...1777
Removal 50-40-1...1777
JOYSTICK PANEL 50-140-1...1777
Removal And Installation 50-140-1...1777
OPERATOR CAB 50-10-1...1777
Removal and Installation 50-10-1...1777
OPERATOR SEAT 50-20-1...1777
Not available at time of printing 50-20-1...1777
PIVOT LINK 50-120-1...1777
Removal And Installation 50-120-1...1777
QUICK TACH 50-90-1...1777
Removal And Installation 50-90-1...1777
REAR WEIGHTS 50-100-1...1777
Removal And Installation 50-100-1...1777
WEAR PADS (FRONT) 50-50-1...1777
Removal And Installation 50-50-1...1777
WEAR PADS (REAR) 50-60-1...1777
Installation 50-60-1...1777
Removal 50-60-1...1777
OPERATOR CAB...1779
Figure 50-10-1...1779
Figure 50-10-2...1779
Figure 50-10-3...1779
Figure 50-10-4...1779
OPERATOR CAB (CONT’D)...1780
Figure 50-10-5...1780
Figure 50-10-6...1780
Figure 50-10-7...1780
OPERATOR CAB (CONT’D)...1781
Figure 50-10-8...1781
Figure 50-10-9...1781
Figure 50-10-10...1781
Figure 50-10-11...1781
OPERATOR CAB (CONT’D)...1782
Figure 50-10-12...1782
Figure 50-10-13...1782
Figure 50-10-14...1782
OPERATOR CAB (CONT’D)...1783
Figure 50-10-15...1783
Figure 50-10-16...1783
Figure 50-10-17...1783
Figure 50-10-18...1783
OPERATOR CAB (CONT’D)...1784
Figure 50-10-19...1784
Figure 50-10-20...1784
Figure 50-10-21...1784
Figure 50-10-22...1784
OPERATOR CAB (CONT’D)...1785
Figure 50-10-23...1785
Figure 50-10-24...1785
Figure 50-10-25...1785
Figure 50-10-26...1785
OPERATOR CAB (CONT’D)...1786
Figure 50-10-27...1786
Figure 50-10-28...1786
Figure 50-10-29...1786
Figure 50-10-30...1786
OPERATOR SEAT...1787
BOOM ASSEMBLY...1789
Figure 50-30-1...1789
Figure 50-30-2...1789
Figure 50-30-3...1789
Figure 50-30-4...1789
BOOM ASSEMBLY (Cont'd)...1790
Figure 50-30-5...1790
Figure 50-30-6...1790
Figure 50-30-7...1790
Figure 50-30-8...1790
BOOM ASSEMBLY (Cont'd)...1791
Figure 50-30-9...1791
Figure 50-30-10...1791
Figure 50-30-11...1791
Figure 50-30-12...1791
BOOM ASSEMBLY (Cont'd)...1792
Figure 50-30-13...1792
INNER BOOM...1793
Figure 50-40-1...1793
Figure 50-40-2...1793
Figure 50-40-3...1793
Figure 50-40-4...1793
INNER BOOM (Cont'd)...1794
Figure 50-40-5...1794
Figure 50-40-6...1794
Figure 50-40-7...1794
INNER BOOM (Cont'd)...1795
Figure 50-40-8...1795
Figure 50-40-9...1795
Figure 50-40-10...1795
Figure 50-40-11...1795
INNER BOOM (Cont'd)...1796
Figure 50-40-12...1796
Figure 50-40-13...1796
Figure 50-40-14...1796
Figure 50-40-15...1796
WEAR PADS (FRONT)...1797
Figure 50-50-16...1797
Figure 50-50-17...1797
Figure 50-50-18...1797
Figure 50-50-19...1797
WEAR PADS (REAR)...1799
Figure 50-60-1...1799
Figure 50-60-2...1799
Figure 50-60-3...1799
Figure 50-60-4...1799
WEAR PADS (REAR) (CONT’D)...1800
Figure 50-60-5...1800
Figure 50-60-6...1800
Figure 50-60-7...1800
Figure 50-60-8...1800
ENGINE COVER...1801
Figure 50-70-1...1801
Figure 50-70-2...1801
Figure 50-70-3...1801
AIR INTAKE COWLING...1803
Figure 50-71-1...1803
Figure 50-71-2...1803
Figure 50-71-3...1803
FUEL TANK...1805
Figure 50-80-1...1805
Figure 50-80-2...1805
Figure 50-80-3...1805
Figure 50-80-4...1805
FUEL TANK (CONT’D)...1806
Figure 50-80-5...1806
Figure 50-80-6...1806
Figure 50-80-7...1806
Figure 50-80-8...1806
FUEL TANK (Cont'd)...1807
Figure 50-80-9...1807
Figure 50-80-10...1807
Figure 50-80-11...1807
Figure 50-80-12...1807
FUEL TANK (Cont'd)...1808
Figure 50-80-13...1808
QUICK TACH...1809
Figure 50-90-1...1809
Figure 50-90-2...1809
Figure 50-90-3...1809
Figure 50-90-4...1809
QUICK TACH (Cont'd)...1810
Figure 50-90-5...1810
Figure 50-90-6...1810
REAR WEIGHTS...1811
Figure 50-100-1...1811
Figure 50-100-2...1811
Figure 50-100-3...1811
Figure 50-100-4...1811
FENDER...1813
Figure 50-110-2...1813
Figure 50-110-3...1813
PIVOT LINK...1815
Figure 50-120-1...1815
Figure 50-120-2...1815
Figure 50-120-3...1815
Figure 50-120-4...1815
PIVOT LINK (Cont'd)...1816
Figure 50-120-5...1816
Figure 50-120-6...1816
Figure 50-120-7...1816
Figure 50-120-8...1816
PIVOT LINK (Cont'd)...1817
Figure 50-120-9...1817
Figure 50-120-10...1817
DASH COVER/STEERING COLUMN COVER...1819
Figure 50-130-1...1819
Figure 50-130-2...1819
Figure 50-130-3...1819
Figure 50-130-4...1819
DASH COVER/STEERING COLUMN COVER (Cont'd)...1820
Figure 50-130-5...1820
Figure 50-130-6...1820
Figure 50-130-7...1820
Figure 50-130-8...1820
DASH COVER/STEERING COLUMN COVER (Cont'd)...1821
Figure 50-130-9...1821
JOYSTICK PANEL...1823
Figure 50-140-1...1823
Figure 50-140-2...1823
Figure 50-140-3...1823
Figure 50-140-4...1823
ELECTRICAL SYSTEM AND ANALYSIS...1825
ALTERNATOR 60-30-1...1825
Removal And Installation 60-30-1...1825
BATTERY 60-20-1...1825
Removal And Installation 60-20-1...1825
Servicing 60-20-2...1825
Using A Booster Battery (Jump Starting) 60-20-3...1825
BRAKE LIGHT SWITCH 60-100-1...1825
Adjustment 60-100-1...1825
Removal And Installation 60-100-1...1825
ELECTRICAL SYSTEM INFORMATION 60-10-1...1825
Description 60-10-2...1825
Fuses, Diodes & Relays 60-10-2...1825
Troubleshooting Chart 60-10-1...1825
FRAME LEVEL SPEED SWITCH 60-170-1...1825
Description 60-170-1...1825
Disassembly And Assembly 60-170-3...1825
Installation 60-170-2...1825
Removal 60-170-1...1825
FRONT WIPER MOTOR 60-110-1...1825
Removal And Installation 60-110-1...1825
INCHING SWITCH 60-150-1...1825
Adjustment 60-150-1...1825
Removal And Installation 60-150-1...1825
INSTRUMENT PANEL 60-80-1...1825
Removal And Installation 60-80-1...1825
LIGHTS 60-60-1...1825
Front Light Removal And Installation 60-60-2...1825
Rear Light Removal And Installation 60-60-1...1825
Longitudinal Stability Indicator Calibration 60-180-1...1825
Fitting the sensor 60-180-1...1825
Calibration procedure 60-180-1...1825
PEDAL ASSEMBLY 60-140-1...1825
Disassembly And Assembly 60-140-2...1825
Removal And Installation 60-140-1...1825
Continued On Next Page...1825
ELECTRICAL SYSTEM AND ANALYSIS (Cont’d)...1826
REAR WIPER MOTOR 60-130-1...1826
Removal And Installation 60-130-1...1826
SERVICE SOFTWARE 60-160-1...1826
Calibrate Inch Pedal 60-160-5...1826
Connecting The Laptop Computer 60-160-1...1826
Entering The Service Software 60-160-2...1826
Monitor Screen 60-160-3...1826
Warnings Screen 60-160-4...1826
STARTER 60-40-1...1826
Removal And Installation 60-40-1...1826
Parts Identification 60-40-2...1826
Assembly/disassembly 60-40-3...1826
SWITCH PANEL 60-90-1...1826
Parts description 60-90-1...1826
TOP WIPER MOTOR 60-120-1...1826
Removal And Installation 60-120-1...1826
TRAVEL/SIGNAL LEVER 60-70-1...1826
Removal And Installation 60-70-1...1826
Longitudinal Stability Indicator Calibration 60-180-1...1826
Fitting the sensor 60-180-1...1826
Calibration procedure 60-180-1...1826
ELECTRICAL SYSTEM INFORMATION...1827
ELECTRICAL SYSTEM INFORMATION (CONT’D)...1828
Figure 60-10-1...1828
Fuses, Diodes & Relays...1828
Figure 60-10-2...1828
ELECTRICAL SYSTEM (CONT’D)...1829
Figure 60-10-3...1829
ELECTRICAL SYSTEM INFORMATION (CONT’D)...1831
Figure 60-10-4...1831
BATTERY...1833
Figure 60-20-1...1833
Figure 60-20-2...1833
Figure 60-20-3...1833
BATTERY (Cont'd)...1834
Figure 60-20-4...1834
Figure 60-20-5...1834
Figure 60-20-6...1834
BATTERY (Cont'd)...1835
Figure 60-20-7...1835
Figure 60-20-8...1835
ALTERNATOR...1837
Figure 60-30-1...1837
Figure 60-30-2...1837
Figure 60-30-3...1837
Figure 60-30-4...1837
ALTERNATOR (CONT’D)...1838
Figure 60-30-5...1838
Figure 60-30-6...1838
Figure 60-30-7...1838
STARTER...1839
Figure 60-40-2...1839
Figure 60-40-3...1839
Figure 60-40-4...1839
STARTER (CONT’D)...1840
STARTER (CONT’D)...1841
LIGHTS...1843
Figure 60-60-1...1843
Figure 60-60-2...1843
Figure 60-60-3...1843
Figure 60-60-4...1843
LIGHTS (Cont'd)...1844
Figure 60-60-5...1844
Figure 60-60-6...1844
TRAVEL/SIGNAL LEVER...1845
Figure 60-60-1...1845
Figure 60-70-2...1845
Figure 60-70-3...1845
Figure 60-70-4...1845
TRAVEL/SIGNAL LEVER (CONT’D)...1846
Figure 60-70-5...1846
Figure 60-70-6...1846
Figure 60-70-7...1846
INSTRUMENT PANEL...1847
Figure 60-80-1...1847
Figure 60-80-2...1847
Figure 60-80-3...1847
Figure 60-80-4...1847
SWITCH PANEL...1849
Switch PANEL (CONT’D)...1850
1...1850
L.H. control panel plate...1850
2...1850
R.H. control panel plate...1850
3...1850
Screw...1850
4...1850
Instrument panel...1850
5...1850
Bezel...1850
6...1850
Switch, beacon light...1850
7...1850
Warning Switch...1850
8...1850
Heating Control Valve...1850
9...1850
Fan Speed Switch...1850
10...1850
Bezel For outer left and right positions...1850
11...1850
Bezel For middle positions...1850
12...1850
Trailer turn indicator...1850
13...1850
Steering mode indicator...1850
14...1850
Steering mode switch...1850
15...1850
Lever Switch...1850
16...1850
Switch, head lamp...1850
17...1850
Working light switch...1850
18...1850
Fog light switch...1850
19...1850
Blank Plug...1850
20...1850
Switch, rear wiper/washer...1850
21...1850
Switch, roof wiper (Option)...1850
22...1850
Switch, transmission mode...1850
23...1850
Locking switch...1850
24...1850
Switch, aux. hydr...1850
28...1850
Ignition Switch...1850
29...1850
Set of keys (ignition)...1850
30...1850
Knob...1850
31...1850
Set of keys...1850
32...1850
Screw...1850
33...1850
Stability indicator and wire harness...1850
34...1850
Washer...1850
35...1850
Nut...1850
36...1850
Support for frame leveling knob...1850
37...1850
Screw...1850
38...1850
Switch (proportional)...1850
39...1850
Spacer...1850
40...1850
Plate...1850
41...1850
Plug...1850
BRAKE LIGHT SWITCH...1851
Figure 60-100-1...1851
Figure 60-100-2...1851
Figure 60-100-3...1851
FRONT WIPER MOTOR...1853
Figure 60-110-1...1853
Figure 60-110-2...1853
Figure 60-110-3...1853
Figure 60-110-4...1853
FRONT WIPER MOTOR (Cont'd)...1854
Figure 60-110-5...1854
Figure 60-110-6...1854
Figure 60-110-7...1854
Figure 60-110-8...1854
FRONT WIPER MOTOR (Cont'd)...1855
Figure 60-110-9...1855
Figure 60-110-10...1855
TOP WIPER MOTOR...1857
Figure 60-120-1...1857
Figure 60-120-2...1857
Figure 60-120-3...1857
Figure 60-120-4...1857
TOP WIPER MOTOR (Cont'd)...1858
Figure 60-120-5...1858
Figure 60-120-6...1858
Figure 60-120-7...1858
Figure 60-120-8...1858
REAR WIPER MOTOR...1859
Figure 60-130-1...1859
Figure 60-130-2...1859
Figure 60-130-3...1859
Figure 60-130-4...1859
REAR WIPER MOTOR (Cont'd)...1860
Figure 60-130-5...1860
Figure 60-130-6...1860
PEDAL ASSEMBLY...1861
Figure 60-140-1...1861
Figure 60-140-2...1861
Figure 60-140-3...1861
Figure 60-140-4...1861
PEDAL ASSEMBLY (CONT’D)...1862
Figure 60-140-5...1862
Figure 60-140-6...1862
Figure 60-140-7...1862
Figure 60-140-8...1862
PEDAL ASSEMBLY (CONT’D)...1863
Figure 60-140-9...1863
Figure 60-140-10...1863
Figure 60-140-11...1863
Figure 60-140-12...1863
PEDAL ASSEMBLY (CONT’D)...1864
Figure 60-140-13...1864
Figure 60-140-14...1864
Figure 60-140-15...1864
Figure 60-140-16...1864
PEDAL ASSEMBLY (CONT’D)...1865
Figure 60-140-17...1865
INCHING SWITCH...1867
Figure 60-160-1...1867
Figure 60-160-2...1867
Adjustment...1867
Figure 60-160-3...1867
SERVICE SOFTWARE...1869
Figure 60-160-1...1869
Figure 60-160-2...1869
Figure 60-160-3...1869
Figure 60-160-4...1869
SERVICE SOFTWARE (CONT’D)...1870
Figure 60-160-5...1870
Figure 60-160-6...1870
Figure 60-160-7...1870
Figure 60-160-8...1870
SERVICE SOFTWARE (CONT’D)...1871
Figure 60-160-9...1871
Figure 60-160-10...1871
Figure 60-160-11...1871
Figure 60-160-12...1871
SERVICE SOFTWARE (CONT’D)...1872
Figure 60-160-13...1872
Figure 60-160-14...1872
Figure 60-160-15...1872
SERVICE SOFTWARE (CONT’D)...1873
01...1873
Sensor supply voltage-sensor voltage out of range...1873
17...1873
Software did not load properly- Restart program and reload software...1873
18...1873
Inch pedal calibration failed- recalibrate the inch pedal...1873
19...1873
Inch/brake potentiometer-no pedal setup done, value too low, value too high...1873
20...1873
Engine speed pickup-engine speed missed when starting engine...1873
21...1873
Propel current-short cut, open circuit...1873
22...1873
F-N-R switch-short cut between forward and reverse...1873
23...1873
Engine speed pickup-engine speed interrupted...1873
24...1873
Hydro motor propel current-short cut, open circuit...1873
25...1873
Creep drive calibration failed- recalibrate the creep drive potentiometer...1873
26...1873
Creep drive potentiometer-value too low, value too high...1873
27...1873
Motor speed pickup-motor speed interrupted...1873
Figure 60-160-16...1873
Figure 60-160-17...1873
SERVICE SOFTWARE (CONT’D)...1874
Figure 60-160-18...1874
Figure 60-160-19...1874
Figure 60-160-20...1874
FRAME LEVEL SPEED SWITCH...1875
Figure 60-170-1...1875
Figure 60-170-2...1875
Figure 60-170-3...1875
FRAME LEVEL SPEED SWITCH (CONT’D)...1876
Figure 60-170-4...1876
Figure 60-170-5...1876
Figure 60-170-6...1876
Figure 60-170-7...1876
FRAME LEVEL SPEED SWITCH (CONT’D)...1877
Figure 60-170-8...1877
Figure 60-170-9...1877
Longitudinal Stability Indicator Calibration...1879
Figure 60-170-1...1879
Figure 60-170-2...1879
1. Turn off the ignition. Push buzzer button (Item 1) [Figure 60-170-2] and hold it...1879
2. While holding the buzzer button (Item 1) [Figure 60- 170-2] pressed, start the machine. Hold the button for another 5 seconds and release it when the green LED's light up...1879
3. With the machine unloaded and the boom retracted, raise the boom until the maximum angle...1879
4. Wait until the machine stabilizes...1879
5. Push the buzze button (Item 1) [Figure 60-170-2] for 5 seconds and wait until the “STOP” light turns red...1879
6. Lower the boom...1879
7. Take a load that can make the machine tip (do not exceed the maximum authorized load) over and lift it 30 centimeters above the ground...1879
8. Extend the boom till the rear wheels do no longer touch the ground. Use, if needed, the shunt key (located above the contact key)...1879
9. Push the buzzer button (Item 1) [Figure 60-170-2] for 5 seconds and wait until all lights of the indicator turn on...1879
10. If the shunt key has been activated, turn it off now...1879
11. Retract the boom and then extend again to check if the LED's (Item 2) [Figure 60-170-2] light up in the right order and the ...1879
12. Remove the load...1879
ENGINE SERVICE...1881
AIR CLEANER 70-40-1...1881
Housing Removal And Installation 70-40-1...1881
ENGINE AND ENGINE MOUNTS 70-60-1...1881
Removal And Installation 70-60-1...1881
ENGINE COMPONENTS AND TESTING 70-70-1...1881
Checking The Fuel Lift Pump 70-70-9...1881
Compression Checking 70-70-11...1881
Glow Plugs Checking 70-70-12...1881
Glow Plugs Removal And Installation 70-70-12...1881
Fuel Injection Pump Installation 70-70-4...1881
Fuel Injection Pump Removal 70-70-1...1881
Fuel Injectors Removal And Installation 70-70-7...1881
Fuel Lift Pump Removal And Installation 70-70-10...1881
ENGINE/HYDROSTAT ASSEMBLY 70-80-1...1881
Removal And Installation 70-80-1...1881
ENGINE SPEED CONTROL 70-20-1...1881
Removal And Installation 70-20-1...1881
ENGINE TIMING 70-71-1...1881
Procedure 70-71-1...1881
FLYWHEEL AND HOUSING 70-90-1...1881
Removal And Installation 70-90-1...1881
Ring Gear Installation 70-90-4...1881
Ring Gear Removal 70-90-4...1881
MUFFLER 70-30-1...1881
Removal And Installation 70-30-1...1881
OIL COOLER/RADIATOR 70-50-1...1881
Disassembly And Assembly 70-50-3...1881
Removal And Installation 70-50-1...1881
ENGINE SERVICE (CONT’D)...1882
RECONDITIONING THE ENGINE 70-100-1...1882
Camshaft And Tappets Installation 70-100-24...1882
Camshaft And Tappets Removal 70-100-23...1882
Changing Valve Springs (With Cylinder Head Installed) 70-100-17...1882
Checking Crankshaft End Play 70-100-38...1882
Checking Piston Height 70-100-32...1882
Connecting Rod Bushing Replacement 70-100-30...1882
Connecting Rod Inspection 70-100-30...1882
Cooling System Description 70-100-39...1882
Crankshaft And Bearings Description 70-100-33...1882
Crankshaft And Bearings Installation 70-100-35...1882
Crankshaft And Bearings Removal 70-100-33...1882
Crankshaft Pulley Removal And Installation 70-100-19...1882
Cutting A Valve Seat 70-100-15...1882
Cylinder Head Inspection 70-100-8...1882
Cylinder Head Installation 70-100-8...1882
Cylinder Head Removal 70-100-6...1882
Cylinder Liner Inspection 70-100-49...1882
Cylinder Liner Installation 70-100-51...1882
Cylinder Liner Removal 70-100-50...1882
Engine Block Description 70-100-47...1882
Engine Block Disassembly And Assembly 70-100-47...1882
Engine Lubrication System Description 70-100-42...1882
Exhaust Manifold Removal And Installation 70-100-4...1882
Fuel Injector Cover Removal And Installation 70-100-4...1882
Front Oil Seal Removal And Installation 70-100-19...1882
Inspection 70-100-48...1882
Inspection Of Crankshaft And Bearings 70-100-35...1882
Lubricating Oil Cooler Removal And Installation 70-100-40...1882
Oil Filter Adapter Removal And Installation 70-100-43...1882
Oil Pan Removal And Installation 70-100-43...1882
Oil Pressure Relief Valve Disassembly And Assembly 70-100-46...1882
Oil Pump Disassembly And Assembly 70-100-46...1882
Oil Pump Installation 70-100-45...1882
Oil Pump Removal 70-100-44...1882
Oil Screen And Pick-up Tube 70-100-44...1882
ENGINE SERVICE (CONT’D)...1883
RECONDITIONING THE ENGINE 70-100-1...1883
Piston And Connecting Rod Assembly 70-100-30...1883
Piston And Connecting Rod Installation 70-100-30...1883
Piston Cooling Jet Alignment 70-100-48...1883
Piston Cooling Jet Installation 70-100-48...1883
Piston Cooling Jet Removal 70-100-48...1883
Piston Ring End Gap 70-100-28...1883
Piston Ring Groove Clearance 70-100-29...1883
Piston Ring Installation 70-100-28...1883
Pistons And Connecting Rods Description 70-100-26...1883
Pistons And Connecting Rods Disassembly 70-100-28...1883
Pistons And Connecting Rods Removal 70-100-26...1883
Rear Oil Seal Housing Positioning 70-100-37...1883
Rear Oil Seal Installation 70-100-37...1883
Rear Oil Seal Removal 70-100-37...1883
Rocker Cover Removal And Installation 70-100-5...1883
Rocker Shaft Disassembly And Assembly 70-100-11...1883
Thermostat Removal and Installation 70-100-40...1883
Thermostat Testing 70-100-40...1883
Timing Case And Drive Assembly Description 70-100-19...1883
Timing Case And Gear Installation 70-100-21...1883
Timing Case And Gear Removal 70-100-20...1883
Timing Cover Installation 70-100-19...1883
Timing Cover Removal 70-100-19...1883
Turbo Charger Description 70-100-2...1883
Turbo Charger Removal And Installation 70-100-2...1883
Turbo Charger Troubleshooting 70-100-1...1883
Valve Clearance Adjustment 70-100-18...1883
Valve Depth Checking 70-100-12...1883
Valve Guides Checking 70-100-13...1883
Valve Guide Installation 70-100-14...1883
Valve Guide Removal 70-100-14...1883
Valve Removal 70-100-11...1883
Valve Seat Assembly 70-100-16...1883
Valve Springs Checking 70-100-12...1883
Valves Checking 70-100-15...1883
Water Pump Installation 70-100-41...1883
Water Pump Removal 70-100-41...1883
TROUBLESHOOTING 70-10-1...1883
Chart 70-100-1...1883
TROUBLESHOOTING...1885
Chart...1885
The following troubleshooting chart is provided for assistance in location and correcting problems which are most common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only...1885
TROUBLESHOOTING (Cont'd)...1886
Chart (Cont'd)...1886
ENGINE SPEED CONTROL...1887
Figure 70-20-1...1887
Figure 70-20-2...1887
Figure 70-20-3...1887
Figure 70-20-4...1887
MUFFLER...1889
Figure 70-30-1...1889
For S/N 362811001 - 362812000, S/N 362911001 - 362912000:...1889
Figure 70-30-2...1889
For S/N 362812001 and Above, S/N 362912001 and Above:...1889
Figure 70-30-3...1889
AIR CLEANER...1891
Figure 70-40-1...1891
Figure 70-40-2...1891
OIL COOLER/RADIATOR...1893
Figure 70-50-1...1893
Figure 70-50-2...1893
Figure 70-50-3...1893
Figure 70-50-4...1893
OIL COOLER/RADIATOR (CONT’D)...1894
Figure 70-50-5...1894
Figure 70-50-6...1894
Figure 70-50-7...1894
Figure 70-50-8...1894
OIL COOLER/RADIATOR (CONT’D)...1895
Figure 70-50-9...1895
Figure 70-50-10...1895
Figure 70-50-11...1895
Figure 70-50-12...1895
OIL COOLER/RADIATOR (CONT’D)...1896
Figure 70-50-13...1896
ENGINE AND ENGINE MOUNTS...1897
Figure 70-60-1...1897
Figure 70-60-2...1897
Figure 70-60-3...1897
ENGINE AND ENGINE MOUNTS (CONT’D)...1898
Figure 70-60-4...1898
Figure 70-60-5...1898
Figure 70-60-6...1898
Figure 70-60-7...1898
ENGINE AND ENGINE MOUNTS (CONT’D)...1899
Figure 70-60-8...1899
Figure 70-60-9...1899
Figure 70-60-10...1899
Figure 70-60-11...1899
ENGINE AND ENGINE MOUNTS (CONT’D)...1900
Figure 70-60-12...1900
ENGINE COMPONENTS AND TESTING...1901
Figure 70-70-1...1901
Figure 70-70-2...1901
Figure 70-70-3...1901
ENGINE COMPONENTS AND TESTING (CONT'D)...1902
Figure 70-70-4...1902
Figure 70-70-5...1902
Figure 70-70-6...1902
Figure 70-70-7...1902
ENGINE COMPONENTS AND TESTING (CONT'D)...1903
Figure 70-70-8...1903
Figure 70-70-9...1903
Figure 70-70-10...1903
Figure 70-70-11...1903
ENGINE COMPONENTS AND TESTING (CONT'D)...1904
Figure 70-70-12...1904
Figure 70-70-13...1904
Figure 70-70-14...1904
ENGINE COMPONENTS AND TESTING (CONT'D)...1905
Figure 70-70-15...1905
Figure 70-70-16...1905
Figure 70-70-17...1905
Figure 70-70-18...1905
ENGINE COMPONENTS AND TESTING (CONT'D)...1906
Figure 70-70-19...1906
Figure 70-70-20...1906
Figure 70-70-21...1906
Figure 70-70-22...1906
ENGINE COMPONENTS AND TESTING (CONT'D)...1907
Figure 70-70-23...1907
Figure 70-70-24...1907
Figure 70-70-25...1907
Figure 70-70-26...1907
ENGINE COMPONENTS AND TESTING (CONT'D)...1908
Figure 70-70-27...1908
Figure 70-70-28...1908
Figure 70-70-29...1908
Figure 70-70-30...1908
ENGINE COMPONENTS AND TESTING (CONT'D)...1909
Figure 70-70-31...1909
Figure 70-70-32...1909
Figure 70-70-33...1909
Figure 70-70-34...1909
ENGINE COMPONENTS AND TESTING (CONT'D)...1910
Figure 70-70-35...1910
Figure 70-70-36...1910
ENGINE COMPONENTS AND TESTING (CONT'D)...1911
Figure 70-70-37...1911
Figure 70-70-38...1911
Figure 70-70-39...1911
ENGINE COMPONENTS AND TESTING (CONT'D)...1912
Figure 70-70-40...1912
Figure 70-70-41...1912
Figure 70-70-42...1912
Figure 70-70-43...1912
ENGINE COMPONENTS AND TESTING (CONT'D)...1913
Figure 70-70-44...1913
ENGINE TIMING...1915
Figure 70-71-1...1915
Figure 70-71-2...1915
Figure 70-71-3...1915
ENGINE/HYDROSTAT ASSEMBLY...1917
Figure 70-80-1...1917
Figure 70-80-2...1917
Figure 70-80-3...1917
ENGINE/HYDROSTAT ASSEMBLY (CONT'D)...1918
Figure 70-80-4...1918
Figure 70-80-5...1918
Figure 70-80-6...1918
Figure 70-80-7...1918
ENGINE/HYDROSTAT ASSEMBLY (CONT'D)...1919
Figure 70-80-8...1919
Figure 70-80-9...1919
Figure 70-80-10...1919
Figure 70-80-11...1919
ENGINE/HYDROSTAT ASSEMBLY (CONT'D)...1920
Figure 70-80-12...1920
Figure 70-80-13...1920
Figure 70-80-14...1920
Figure 70-80-15...1920
ENGINE/HYDROSTAT ASSEMBLY (CONT'D)...1921
Figure 70-80-16...1921
Figure 70-80-17...1921
Figure 70-80-18...1921
Figure 70-80-19...1921
ENGINE/HYDROSTAT ASSEMBLY (CONT'D)...1922
Figure 70-80-20...1922
Figure 70-80-21...1922
Figure 70-80-22...1922
Figure 70-80-23...1922
ENGINE/HYDROSTAT ASSEMBLY (CONT'D)...1923
Figure 70-80-24...1923
Figure 70-80-25...1923
Figure 70-80-26...1923
ENGINE/HYDROSTAT ASSEMBLY (CONT'D)...1924
Figure 70-80-27...1924
Figure 70-80-28...1924
Figure 70-80-29...1924
Figure 70-80-30...1924
ENGINE/HYDROSTAT ASSEMBLY (CONT'D)...1925
Figure 70-80-31...1925
Figure 70-80-32...1925
Figure 70-80-33...1925
Figure 70-80-34...1925
ENGINE/HYDROSTAT ASSEMBLY (CONT'D)...1926
Figure 70-80-35...1926
Figure 70-80-36...1926
Figure 70-80-37...1926
Figure 70-80-38...1926
ENGINE/HYDROSTAT ASSEMBLY (CONT'D)...1927
Figure 70-80-39...1927
Figure 70-80-40...1927
Figure 70-80-41...1927
ENGINE/HYDROSTAT ASSEMBLY (CONT'D)...1928
Figure 70-80-42...1928
Figure 70-80-43...1928
Figure 70-80-44...1928
Figure 70-80-45...1928
FLYWHEEL AND HOUSING...1929
Figure 70-90-1...1929
Figure 70-90-2...1929
Figure 70-90-3...1929
Figure 70-90-4...1929
FLYWHEEL AND HOUSING (Cont'd)...1930
Figure 70-90-5...1930
Figure 70-90-6...1930
Figure 70-90-7...1930
Figure 70-90-8...1930
FLYWHEEL AND HOUSING (Cont'd)...1931
Figure 70-90-9...1931
Figure 70-90-10...1931
FLYWHEEL AND HOUSING (Cont'd)...1932
Figure 70-90-11...1932
Figure 70-90-12...1932
RECONDITIONING THE ENGINE...1933
Turbo Charger Troubleshooting...1933
The chart below is given to assist in the correct diagnosis of turbocharger faults...1933
If the inside of the intake manifold is wet, check that there is not a fuel leak from the starting aid...1933
RECONDITIONING THE ENGINE (CONT'D)...1934
Figure 70-100-1...1934
Figure 70-100-2...1934
Figure 70-100-3...1934
RECONDITIONING THE ENGINE (CONT'D)...1935
Figure 70-100-4...1935
Figure 70-100-5...1935
Figure 70-100-6...1935
Figure 70-100-7...1935
RECONDITIONING THE ENGINE (CONT'D)...1936
Figure 70-100-8...1936
Figure 70-100-9...1936
Figure 70-100-10...1936
Figure 70-100-11...1936
RECONDITIONING THE ENGINE (CONT'D)...1937
Figure 70-100-12...1937
Figure 70-100-13...1937
Figure 70-100-14...1937
Figure 70-100-15...1937
RECONDITIONING THE ENGINE (CONT'D)...1938
Figure 70-100-16...1938
Figure 70-100-17...1938
Figure 70-100-18...1938
Figure 70-100-19...1938
RECONDITIONING THE ENGINE (CONT'D)...1939
Figure 70-100-20...1939
Figure 70-100-21...1939
Figure 70-100-22...1939
Figure 70-100-23...1939
RECONDITIONING THE ENGINE (CONT'D)...1940
Figure 70-100-24...1940
Figure 70-100-25...1940
RECONDITIONING THE ENGINE (CONT'D)...1941
Figure 70-100-26...1941
Figure 70-100-27...1941
Figure 70-100-28...1941
Figure 70-100-29...1941
RECONDITIONING THE ENGINE (CONT'D)...1942
Figure 70-100-30...1942
Figure 70-100-31...1942
Figure 70-100-32...1942
Figure 70-100-33...1942
RECONDITIONING THE ENGINE (CONT'D)...1943
Figure 70-100-34...1943
Shaft O.D...1943
0.9828-0.9837 inch (24,96-24,99 mm)...1943
Rocker Arm Bore Dia...1943
0.9848-09.863 inch (25,02-25,05 mm)...1943
Clearance Between Rocker Arm & Shaft...1943
0.0010-0.0035 inch (0,026-0,089 mm)...1943
Figure 70-100-35...1943
RECONDITIONING THE ENGINE (CONT'D)...1944
Figure 70-100-36...1944
Valve Springs...1944
Compressed Height...1944
1.358 inch (34,5 mm)...1944
Installed Pressure...1944
51 ft.-lbs. (229 N)...1944
Figure 70-100-37...1944
RECONDITIONING THE ENGINE (CONT'D)...1945
Figure 70-100-38...1945
Figure 70-100-39...1945
Inside Diameter...1945
(Item 1) [Figure 70-100-38]...1945
0.3543-0.3552 inch (9,00-9,02 mm)...1945
Outside Diameter (Item 2) [Figure 70-100-38]...1945
Intake & Exhaust...1945
0.5131-0.5137 inch (13,04-13,05 mm)...1945
Overall Diameter (Item 3) [Figure 70-100-38]...1945
Intake & Exhaust...1945
2.008-2.028 inch (51,00-51,50 mm)...1945
Protrusion from bottom recess for valve spring;...1945
(Item 4) [Figure 70-100-38]...1945
0.486-0.498 inch (12,35-12,65 mm)...1945
RECONDITIONING THE ENGINE (CONT'D)...1946
Figure 70-100-40...1946
Figure 70-100-41...1946
RECONDITIONING THE ENGINE (CONT'D)...1947
Figure 70-100-42...1947
Valve Seat Angle...1947
30...1947
Figure 70-100-43...1947
RECONDITIONING THE ENGINE (CONT'D)...1948
Figure 70-100-44...1948
RECONDITIONING THE ENGINE (CONT'D)...1949
Figure 70-100-45...1949
Figure 70-100-46...1949
RECONDITIONING THE ENGINE (CONT'D)...1950
Figure 70-100-47...1950
0.008 inch (0,20 mm)...1950
Intake...1950
0.018 inch (0,45 mm)...1950
Exhaust...1950
Figure 70-100-48...1950
Figure 70-100-49...1950
a...1950
With the rocker arm rocking (valves 7 & 8) on No. 4 cylinder set clearance at No. 1 cylinder (valves 1 & 2)...1950
b...1950
With the rocker arm rocking (valves 3 & 4) on No. 2 cylinder set clearance at No. 3 cylinder (valves 5 & 6)...1950
c...1950
With the rocker arm rocking (valves 1 & 2) on No. 1 cylinder set clearance at No. 4 cylinder (valves 7 & 8)...1950
d...1950
With the rocker arm rocking (valves 5 & 6) on No. 3 cylinder set clearance at No. 2 cylinder (valves 3 & 4)...1950
RECONDITIONING THE ENGINE (CONT'D)...1951
Figure 70-100-50...1951
Figure 70-100-51...1951
Figure 70-100-52...1951
RECONDITIONING THE ENGINE (CONT'D)...1952
Figure 70-100-53...1952
Figure 70-100-54...1952
Figure 70-100-55...1952
Figure 70-100-56...1952
RECONDITIONING THE ENGINE (CONT'D)...1953
Figure 70-100-57...1953
Figure 70-100-58...1953
Figure 70-100-59...1953
Figure 70-100-60...1953
RECONDITIONING THE ENGINE (CONT'D)...1954
Figure 70-100-61...1954
Figure 70-100-62...1954
Figure 70-100-63...1954
Figure 70-100-64...1954
RECONDITIONING THE ENGINE (CONT'D)...1955
Figure 70-100-65...1955
Figure 70-100-66...1955
Figure 70-100-67...1955
RECONDITIONING THE ENGINE (CONT'D)...1956
Figure 70-100-68...1956
Figure 70-100-69...1956
Figure 70-100-70...1956
RECONDITIONING THE ENGINE (CONT'D)...1957
Figure 70-100-71...1957
RECONDITIONING THE ENGINE (Cont'd)...1958
Figure 70-100-72...1958
Figure 70-100-73...1958
Figure 70-100-74...1958
RECONDITIONING THE ENGINE (Cont'd)...1959
Figure 70-100-75...1959
RECONDITIONING THE ENGINE (Cont'd)...1960
Figure 70-100-76...1960
Figure 70-100-77...1960
Figure 70-100-78...1960
Figure 70-100-79...1960
RECONDITIONING THE ENGINE (Cont'd)...1961
Figure 70-100-80...1961
Figure 70-100-81...1961
RECONDITIONING THE ENGINE (Cont'd)...1962
Figure 70-100-82...1962
Figure 70-100-83...1962
Figure 70-100-84...1962
RECONDITIONING THE ENGINE (Cont'd)...1963
Figure 70-100-85...1963
Figure 70-100-86...1963
Figure 70-100-87...1963
Figure 70-100-88...1963
RECONDITIONING THE ENGINE (Cont'd)...1964
Figure 70-100-89...1964
RECONDITIONING THE ENGINE (Cont'd)...1965
Figure 70-100-90...1965
Figure 70-100-91...1965
Figure 70-100-92...1965
RECONDITIONING THE ENGINE (Cont'd)...1966
Figure 70-100-93...1966
Figure 70-100-94...1966
Figure 70-100-95...1966
Figure 70-100-96...1966
RECONDITIONING THE ENGINE (Cont'd)...1967
Figure 70-100-97...1967
Figure 70-100-98...1967
Figure 70-100-99...1967
RECONDITIONING THE ENGINE (Cont'd)...1968
Figure 70-100-100...1968
Figure 70-100-101...1968
Figure 70-100-102...1968
RECONDITIONING THE ENGINE (Cont'd)...1969
Figure 70-100-103...1969
Figure 70-100-104...1969
Figure 70-100-105...1969
RECONDITIONING THE ENGINE (Cont'd)...1970
Figure 70-100-106...1970
Figure 70-100-107...1970
Figure 70-100-108...1970
Figure 70-100-109...1970
RECONDITIONING THE ENGINE (Cont'd)...1971
Figure 70-100-110...1971
Figure 70-100-111...1971
Figure 70-100-112...1971
RECONDITIONING THE ENGINE (Cont'd)...1972
Figure 70-100-113...1972
Figure 70-100-114...1972
Figure 70-100-115...1972
RECONDITIONING THE ENGINE (Cont'd)...1973
Figure 70-100-116...1973
RECONDITIONING THE ENGINE (Cont'd)...1974
Figure 70-100-117...1974
Figure 70-100-118...1974
Figure 70-100-119...1974
RECONDITIONING THE ENGINE (Cont'd)...1975
Figure 70-100-120...1975
Figure 70-100-121...1975
Figure 70-100-122...1975
RECONDITIONING THE ENGINE (Cont'd)...1976
Figure 70-100-123...1976
Figure 70-100-124...1976
Figure 70-100-125...1976
RECONDITIONING THE ENGINE (Cont'd)...1977
Figure 70-100-126...1977
Figure 70-100-127...1977
RECONDITIONING THE ENGINE (Cont'd)...1978
Figure 70-100-128...1978
Figure 70-100-129...1978
Figure 70-100-130...1978
Figure 70-100-131...1978
RECONDITIONING THE ENGINE (Cont'd)...1979
Figure 70-100-132...1979
Figure 70-100-133...1979
RECONDITIONING THE ENGINE (Cont'd)...1980
Figure 70-100-134...1980
Figure 70-100-135...1980
Figure 70-100-136...1980
RECONDITIONING THE ENGINE (Cont'd)...1981
Figure 70-100-137...1981
Figure 70-100-138...1981
RECONDITIONING THE ENGINE (Cont'd)...1982
Figure 70-100-139...1982
RECONDITIONING THE ENGINE (Cont'd)...1983
Figure 70-100-140...1983
Figure 70-100-141...1983
HEATING, VENTILATION, AIR CONDITIONING...1985
AIR CONDITIONING SERVICE 80-90-1...1985
Chart 80-90-1...1985
AIR CONDITIONING SYSTEM FLOW 80-10-2...1985
Principals 80-10-2...1985
BASIC TROUBLESHOOTING 80-50-1...1985
Checking The Electrical System 80-50-2...1985
Compressor Drive Belt Inspection 80-50-1...1985
Poor A/C Performance 80-50-1...1985
COMPONENTS 80-20-1...1985
Identification 80-20-1...1985
COMPRESSOR 80-110-1...1985
Compressor Clutch Disassembly And Assembly 80-110-2...1985
Removal And Installation 80-110-1...1985
CONDENSER 80-120-1...1985
Removal And Installation 80-120-1...1985
EVAPORATOR/BLOWER UNIT 80-150-1...1985
Removal And Installation 80-150-1...1985
EXPANSION VALVE 80-160-1...1985
Removal And Installation 80-160-1...1985
GENERAL AIR CONDITIONING SERVICE GUIDELINES 80-60-1...1985
Component Replacement And Refrigeration Leaks 80-60-2...1985
Compressor Oil 80-60-1...1985
Compressor Oil Check 80-60-1...1985
HEATER ASSEMBLY 80-170-1...1985
Core Removal And Installation 80-170-2...1985
Fan Removal And Installation 80-170-2...1985
Removal And Installation 80-170-1...1985
PRESSURE SWITCH 80-140-1...1985
Removal And Installation 80-140-1...1985
RECEIVER/DRIER 80-130-1...1985
Removal And Installation 80-130-1...1985
Continued On Next Page...1985
HEATING, VENTILATION, AIR CONDITIONING (Cont’d)...1986
REGULAR MAINTENANCE 80-40-1...1986
Cleaning The Condenser 80-40-2...1986
Compressor Drive Belt Inspection 80-40-2...1986
Filter Element Removal And Installation 80-40-1...1986
SAFETY 80-30-1...1986
Safety Equipment 80-30-1...1986
SYSTEM CHARGING AND RECLAMATION 80-100-1...1986
Charging Procedure 80-100-5...1986
Charging Procedure With A Manifold Gauge Set 80-100-4...1986
Reclamation Procedure 80-100-1...1986
SYSTEM TROUBLESHOOTING CHART 80-70-1...1986
TEMPERATURE/PRESSURE 80-80-1...1986
Chart 80-80-1...1986
AIR CONDITIONING SYSTEM FLOW...1988
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit. At these five points in the system the refrigerant goes through pressure and temperature changes...1988
The compressor (Item 1) Page 80-10-3 takes in heated, low pressure refrigerant gas through the suction valve (low pressure side)...1988
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the refrigerant from a gas to a liquid...1988
The liquid refrigerant moves on to the receiver/drier (Item 3) Page 80-10-3 where impurities such as moisture and dirt are filte...1988
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) Page 80-10-3. As the refrigerant passes t...1988
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor...1988
AIR CONDITIONING SYSTEM FLOW (Cont'd)...1989
Chart...1989
COMPONENTS...1991
Figure 80-20-1...1991
Figure 80-20-2...1991
Figure 80-20-3...1991
Figure 80-20-4...1991
COMPONENTS (Cont'd)...1992
Figure 80-20-5...1992
Figure 80-20-6...1992
Figure 80-20-7...1992
SAFETY...1993
Figure 80-30-1...1993
Figure 80-30-2...1993
REGULAR MAINTENANCE...1995
Figure 80-40-1...1995
REGULAR MAINTENANCE (Cont'd)...1996
Figure 80-40-2...1996
Cleaning The Condenser...1996
Figure 80-40-3...1996
BASIC TROUBLESHOOTING...1997
Figure 80-50-1...1997
Figure 80-50-2...1997
Figure 80-50-3...1997
BASIC TROUBLESHOOTING (Cont'd)...1998
Figure 80-50-4...1998
Figure 80-50-5...1998
Figure 80-50-6...1998
Figure 80-50-7...1998
BASIC TROUBLESHOOTING (Cont'd)...1999
Figure 80-50-8...1999
Figure 80-50-9...1999
Figure 80-50-10...1999
Figure 80-50-11...1999
BASIC TROUBLESHOOTING (Cont'd)...2000
Figure 80-50-12...2000
Figure 80-50-13...2000
Figure 80-50-14...2000
Figure 80-50-15...2000
BASIC TROUBLESHOOTING (Cont'd)...2001
Figure 80-50-16...2001
Figure 80-50-17...2001
Figure 80-50-18...2001
Figure 80-50-19...2001
GENERAL AIR CONDITIONING SERVICE GUIDELINES...2003
Figure 80-60-20...2003
The compressor (Item 1) [Figure 80-60-20] is factory filled with 150-170 cc's of PAG oil (Poly Alkelene Glycol)...2003
Unlike engine oil, it is not necessary to frequently check or change the compressor oil...2003
It is necessary to check, replenish or replace the compressor oil in the following cases:...2003
1. When the evaporator, condenser or receiver-drier is replaced...2003
2. When refrigerant has leaked from the system...2003
3. When refrigerant is suddenly released from the cooling cycle...2003
4. When any related problems occur in the cooling cycle...2003
When one of the components (the evaporator, condenser or receiver-drier) is replaced, one ounce (30 cc) of PAG oil should be added for each component replaced...2003
If the A/C compressor is changed, no oil should be added to the system, because the compressor comes factory filled with oil...2003
The compressor oil should be checked as follows when oil is being added to an in service machine...2003
There is a close affinity between oil and refrigerant. During normal operation, part of the oil circulates with the refrigerant ...2003
If the amount of refrigerant in the system has decreased, charge the system. (See “SYSTEM CHARGING AND RECLAMATION” on page 80-100-1)...2003
Open the cab door and windows...2003
Run the blower fan at maximum speed...2003
Run the compressor for at least 20 minutes at 800-1200 RPM...2003
Remove the compressor from the machine. (See “COMPRESSOR” on page 80-110-1)...2003
Figure 80-60-21...2003
Figure 80-60-22...2003
Remove the oil drain plug (Item 1) [Figure 80-60-21] and drain the oil through the connectors and the oil drain hole (Item 1) [Figure 80-60-22]...2003
Installation: Tighten the oil drain plug to 9.4-10.8 ft.-lbs. (13-15 Nm) torque...2003
GENERAL AIR CONDITIONING SERVICE GUIDELINES (Cont'd)...2004
Figure 80-60-23...2004
Measure the drained oil in a measuring cylinder...2004
Check the oil for contamination, dirt, metal shavings, or varnish color, discard the oil if contaminated...2004
Figure 80-60-24...2004
Add new compressor oil through the suction side connector (Item 1) [Figure 80-60-24]...2004
Installation: Add 150-170 cc's of PAG oil...2004
Figure 80-60-25...2004
Whenever the A/C system is opened to the atmosphere or there has been a leak in the system, the receiver/drier (Item 1) [Figure 80-60-25] must be changed...2004
Never leave hose fittings, compressor fittings or components uncapped while working on the A/C system...2004
SYSTEM TROUBLESHOOTING CHART...2005
Blower motor does not operate...2005
Blower motor operates normally, but air flow is insufficient...2005
Insufficient cooling although air flow and compressor operation are normal...2005
The compressor does not operate at all, or operates improperly...2005
Magnetic clutch related...2005
SYSTEM TROUBLESHOOTING CHART (Cont'd)...2006
Gauge Pressure Related Troubleshooting...2006
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86-96 degrees F (30-38 degrees C) and compressor speed of approximately 2000 RPM are:...2006
High pressure side pressure: 210-265 PSI...2006
Low pressure side pressure: 15-33 PSI...2006
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure...2006
SYSTEM TROUBLESHOOTING CHART (Cont'd)...2007
Gauge Pressure Related Troubleshooting (Cont’d)...2007
TEMPERATURE/PRESSURE...2009
16...2009
15.69...2009
18...2009
17.04...2009
20...2009
18.43...2009
22...2009
19.87...2009
24...2009
21.35...2009
26...2009
22.88...2009
28...2009
24.47...2009
30...2009
26.10...2009
32...2009
27.79...2009
34...2009
29.52...2009
36...2009
31.32...2009
38...2009
33.17...2009
40...2009
35.07...2009
42...2009
37.03...2009
44...2009
39.05...2009
45...2009
40.09...2009
50...2009
45.48...2009
55...2009
51.27...2009
60...2009
57.47...2009
65...2009
64.10...2009
70...2009
71.19...2009
75...2009
78.75...2009
80...2009
86.80...2009
85...2009
95.40...2009
90...2009
104.40...2009
91...2009
106.30...2009
92...2009
108.20...2009
93...2009
110.20...2009
94...2009
112.10...2009
95...2009
114.10...2009
100...2009
124.30...2009
102...2009
128.50...2009
104...2009
132.90...2009
106...2009
137.30...2009
108...2009
141.90...2009
110...2009
146.50...2009
112...2009
151.30...2009
114...2009
156.10...2009
116...2009
161.10...2009
118...2009
166.10...2009
120...2009
171.30...2009
122...2009
176.60...2009
124...2009
182.00...2009
126...2009
187.50...2009
128...2009
193.10...2009
130...2009
198.90...2009
135...2009
213.70...2009
140...2009
229.40...2009
145...2009
245.80...2009
150...2009
263.00...2009
155...2009
281.10...2009
160...2009
300.10...2009
165...2009
320.10...2009
170...2009
340.80...2009
Evaporator...2009
Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air coming off the coil add 8-10 degrees F. to the temperature on the chart...2009
Condenser...2009
Temperatures are not ambient temperatures but condensing temperatures. Add 40 degrees F. to the ambient temperature to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient temperature...2009
Example: Ambient Temperature=90 degrees F...2009
90 degrees F...2009
+40 degrees F...2009
Conditions and pressures will vary from system to system...2009
AIR CONDITIONING SERVICE...2011
SYSTEM CHARGING AND RECLAMATION...2013
Figure 80-100-1...2013
Figure 80-100-2...2013
Figure 80-100-3...2013
SYSTEM CHARGING AND RECLAMATION (Cont'd)...2014
Figure 80-100-4...2014
Figure 80-100-5...2014
SYSTEM CHARGING AND RECLAMATION (Cont'd)...2015
Figure 80-100-6...2015
Figure 80-100-7...2015
Figure 80-100-8...2015
SYSTEM CHARGING AND RECLAMATION (Cont'd)...2016
Figure 80-100-9...2016
Figure 80-100-10...2016
Figure 80-100-11...2016
SYSTEM CHARGING AND RECLAMATION (Cont'd)...2017
Figure 80-100-12...2017
Figure 80-100-13...2017
Figure 80-100-14...2017
SYSTEM CHARGING AND RECLAMATION (Cont'd)...2018
Figure 80-100-15...2018
Figure 80-100-16...2018
Figure 80-100-17...2018
COMPRESSOR...2019
Figure 80-110-1...2019
Figure 80-110-2...2019
Figure 80-110-3...2019
Figure 80-110-4...2019
COMPRESSOR (Cont'd)...2020
Figure 80-110-5...2020
Figure 80-110-6...2020
Figure 80-110-7...2020
Figure 80-110-8...2020
COMPRESSOR (Cont'd)...2021
Figure 80-110-9...2021
Figure 80-110-10...2021
Figure 80-110-11...2021
Figure 80-110-12...2021
COMPRESSOR (Cont'd)...2022
Figure 80-110-13...2022
Figure 80-110-14...2022
Figure 80-110-15...2022
Figure 80-110-16...2022
COMPRESSOR (Cont'd)...2023
Figure 80-110-17...2023
Figure 80-110-18...2023
CONDENSER...2025
Figure 80-120-1...2025
Figure 80-120-2...2025
Figure 80-120-3...2025
RECEIVER/DRIER...2027
Figure 80-130-1...2027
Figure 80-130-2...2027
PRESSURE SWITCH...2029
Figure 80-140-1...2029
Figure 80-140-2...2029
EVAPORATOR/BLOWER UNIT...2031
Figure 80-150-1...2031
Figure 80-150-2...2031
Figure 80-150-3...2031
Figure 80-150-4...2031
EVAPORATOR/BLOWER UNIT (Cont'd)...2032
Figure 80-150-5...2032
Figure 80-150-6...2032
Figure 80-150-7...2032
Figure 80-150-8...2032
EXPANSION VALVE...2033
Figure 80-160-9...2033
Figure 80-160-10...2033
Figure 80-160-11...2033
Figure 80-160-12...2033
EXPANSION VALVE (Cont'd)...2034
Figure 80-160-13...2034
Figure 80-160-14...2034
HEATER ASSEMBLY...2035
Figure 80-170-1...2035
Figure 80-170-2...2035
Figure 80-170-3...2035
Figure 80-170-4...2035
HEATER ASSEMBLY (Cont'd)...2036
Figure 80-170-5...2036
Figure 80-170-6...2036
Figure 80-170-7...2036
Figure 80-170-8...2036
HEATER ASSEMBLY (Cont'd)...2037
Figure 80-170-9...2037
Figure 80-170-10...2037
Figure 80-170-11...2037
Figure 80-170-12...2037
HEATER ASSEMBLY (Cont'd)...2038
Figure 80-170-13...2038
Figure 80-170-14...2038
SPECIFICATIONS...2039
CONVERSIONS SPEC-70-1...2039
Decimal And Millimeter Equivalents SPEC-70-1...2039
U.S. To Metric Conversion SPEC-70-2...2039
ENGINE SPECIFICATIONS SPEC-20-1...2039
Camshaft And Thrust Washer SPEC-20-6...2039
Connecting Rods And Bearings SPEC-20-4...2039
Crankshaft SPEC-20-4...2039
Crankshaft Re-Grind Data SPEC-20-5...2039
Cylinder Block SPEC-20-6...2039
Cylinder Head SPEC-20-1...2039
Cylinder Liners SPEC-20-7...2039
Engine Torque Component SPEC-20-11...2039
Exhaust Valves SPEC-20-2...2039
Flywheel SPEC-20-9...2039
Fuel Injection Pump SPEC-20-7...2039
Fuel Injectors SPEC-20-7...2039
Fuel Lift Pump SPEC-20-7...2039
General SPEC-20-1...2039
Intake Valves SPEC-20-2...2039
Main Bearings SPEC-20-6...2039
Oil Pump, Gear And Relief Valve SPEC-20-9...2039
Pistons And Piston Rings SPEC-20-3...2039
Rocker Shaft, Rockers And Bushings SPEC-20-3...2039
Thrust Washers SPEC-20-6...2039
Timing Case And Timing Gears SPEC-20-8...2039
Turbocharger SPEC-20-9...2039
Valve Guides SPEC-20-1...2039
Valve Springs SPEC-20-2...2039
Water Pump And Thermostat SPEC-20-10...2039
HYDRAULIC CONNECTION SPECIFICATIONS SPEC-50-1...2039
Flare Fitting SPEC-50-2...2039
O-ring Face Seal Connection SPEC-50-1...2039
O-ring Flare Fitting SPEC-50-3...2039
Port Seal Fitting SPEC-50-5...2039
Straight Thread O-ring Fitting SPEC-50-1...2039
Tubelines And Hoses SPEC-50-1...2039
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS SPEC-60-1...2039
Specifications SPEC-60-1...2039
SPECIFICATIONS (CONT’D)...2040
MACHINE TORQUE SPECIFICATIONS SPEC-30-1...2040
Axle SPEC-30-1...2040
Boom SPEC-30-1...2040
Drive Box SPEC-30-1...2040
Drive Motor SPEC-30-1...2040
Engine SPEC-30-2...2040
Hydraulic Pump SPEC-30-2...2040
TORQUE SPECIFICATIONS FOR BOLTS SPEC-40-1...2040
Torque For General Metric Bolts SPEC-40-2...2040
Torque for General SAE Bolts SPEC-40-1...2040
Telescopic Handler SPECIFICATIONS SPEC-10-1...2040
Capacities SPEC-10-3...2040
Controls SPEC-10-2...2040
Dimensional Specifications SPEC-10-1...2040
Drive System SPEC-10-2...2040
Electrical System SPEC-10-3...2040
Engine SPEC-10-2...2040
Hydraulic System SPEC-10-3...2040
Instrument Panel SPEC-10-3...2040
Performance Specifications SPEC-10-2...2040
Tires SPEC-10-3...2040
Telescopic Handler SPECIFICATIONS...2041
. All dimensions are shown in millimetres. Respective metric dimensions are given in millimeters enclosed by parentheses...2041
. Where applicable, specifications conform to SAE, ASME or ISO standards and are subject to change without notice...2041
Dimensional Specifications...2041
A...2041
2372 mm...2041
2372 mm...2041
B...2041
1798 mm...2041
1798 mm...2041
C...2041
2215 mm...2041
2215 mm...2041
D...2041
2850 mm...2041
2850 mm...2041
E...2041
4143 mm...2041
4143 mm...2041
F...2041
4969 mm...2041
4969 mm...2041
G...2041
513 mm...2041
513 mm...2041
H...2041
5066 mm...2041
5066 mm...2041
J...2041
1400 mm...2041
1400 mm...2041
K...2041
3885 mm...2041
3885 mm...2041
L...2041
7205 mm...2041
7205 mm...2041
M...2041
1395 mm...2041
1395 mm...2041
Telescopic Handler SPECIFICATIONS (CONT’D)...2042
T3571...2042
T3571L...2042
15,300 lbs. (6,940 kg)...2042
*7716 lbs. (3500 kg)...2042
*Rated Load Capacity can change depending on which approved attachment is used...2042
Travel Speed...2042
T3571...2042
T3571L...2042
Low Range...2042
0-4.4 mph (7.1 km/hr)...2042
0-4.4 mph (7.1 km/hr)...2042
High Range...2042
0-18.7 mph (30,1 km/hr)...2042
0-18.7 mph (30,1 km/hr)...2042
Telescopic Handler SPECIFICATIONS (CONT’D)...2043
T3571...2043
T3571L...2043
TITAN 400/70x20 150B 166A2 LIFT RIGGER II (4 bar front/rear)...2043
TITAN 400/70x20 150B 166A2 LIFT RIGGER II (4 bar front/rear)...2043
Optional Tires...2043
DUNLOP 400/80x24 153B T37 TL (4.25 bar front/rear)...2043
DUNLOP 400/80x24 153B T37 TL (4.25 bar front/ rear)...2043
DUNLOP 405/70x20 MPT 152J 168A2 SP T9 (5.5 bar front/rear)...2043
DUNLOP 405/70x20 MPT 152J 168A2 SP T9 (5.5 bar front/rear)...2043
MICHELIN 440/70x24 XM37 150A8 147B (3.5 bar front/rear)...2043
MICHELIN 440/70x24 XM37 150A8 147B (3.5 bar front/rear)...2043
T3571...2043
T3571L...2043
Type...2043
Fuel Tank...2043
Hyd./Hydros. System...2043
33 gals. (125 L)...2043
EQUIVIS ZS 46...2043
Eng. Cooling System...2043
Engine Oil Change w/Filter...2043
9 qts. (8,5 L)...2043
See oil chart...2043
Front Axle...2043
11.1 qts (10,5 L)...2043
100032-06A...2043
Rear Axle...2043
11 qts. (10 L)...2043
100032-06A...2043
Front Reduction Gearbox...2043
0.85 qts. (0,8 L)...2043
100032-06A...2043
Planetary Carrier...2043
1.3 qts. (1,3 L)...2043
1.3 qts. (1,3 L)...2043
100032-06A...2043
T3571...2043
Engine driven, 25 GPM (95 L/min)...2043
3843 PSI (265 Bar)...2043
Auxiliary Flow...2043
@ High idle 0-21 GPM (0-80 L/min)...2043
12 V - 105 Ah - 700A...2043
Full compliment of instrumentation for engine, hydraulic and machine functions...2043
ENGINE SPECIFICATIONS...2045
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses...2045
General...2045
Cylinder Head...2045
Valve Guides...2045
Valve Guide Clearance In The Cylinder Head (Interference)...2045
5.076-5.093 (128,92-129,37)...2045
5.075-5.093 (128,92-129,37)...2045
0.486-0.498 (12,35-12,65)...2045
ENGINE SPECIFICATIONS (Cont'd)...2046
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses...2046
Exhaust Valves...2046
Intake Valves...2046
Valve Springs...2046
Number Of Active Coils...2046
ENGINE SPECIFICATIONS (Cont'd)...2047
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses...2047
Rocker Shaft, Rockers And Bushings...2047
Pistons And Piston Rings...2047
ENGINE SPECIFICATIONS (Cont'd)...2048
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses...2048
Connecting Rods And Bearings...2048
Crankshaft...2048
ENGINE SPECIFICATIONS (Cont'd)...2049
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses...2049
Crankshaft (Cont'd)...2049
With the crankshaft on V-blocks check the maximum run-out of the journals. They must not exceed these specifications below and the difference in run-out between journals must not exceed 0.004 (0,10)...2049
Crankshaft Re-Grind Data...2049
The finished sizes for crankshaft journals which have been ground undersize are given in the table below:...2049
1...2049
2.9884-2.9892...2049
(75.909-75.930)...2049
2.9784-2.96792...2049
(75,649-75,670)...2049
2.9684-2.9692...2049
(75,399-75,420)...2049
2...2049
2.488-2.4896...2049
(63,220-63,240)...2049
2.4788-2.4796...2049
(62,962-62,982)...2049
2.4688-2.4696...2049
(62,708-62,728)...2049
3...2049
1.554 (39,47) maximum...2049
-...2049
-...2049
4...2049
1.474 (37,44) maximum...2049
-...2049
-...2049
5...2049
1.759 (44,68) maximum...2049
-...2049
-...2049
6...2049
1.596 (40,55) maximum...2049
-...2049
-...2049
7...2049
Do not machine this diameter...2049
-...2049
-...2049
8...2049
Do not machine this diameter...2049
-...2049
-...2049
9...2049
0.1448-0.1452 (3,68-3,69)...2049
-...2049
-...2049
Crankshaft Heat Treatment: 60 Hour Nitride...2049
NOTE: Crankshafts that have been nitrided for 60 hours can be machined 0.010 (0,25) without the need to harden again. Check the ...2049
ENGINE SPECIFICATIONS (Cont'd)...2050
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses...2050
Main Bearings...2050
Bearing Undersize Available...2050
-0.010 (-0,25) -0.020 (-0,50) -0.030 (-0,75)...2050
Thrust Washers...2050
Camshaft And Thrust Washer...2050
Camshaft End Play (Production)...2050
Cylinder Block...2050
ENGINE SPECIFICATIONS (Cont'd)...2051
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses...2051
Cylinder Liners...2051
Fuel Injection Pump...2051
Fuel Injectors...2051
Fuel Lift Pump...2051
Electrically operated...2051
Electric Motor 12V/24V...2051
ENGINE SPECIFICATIONS (Cont'd)...2052
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses...2052
Timing Case And Timing Gears...2052
68...2052
Fuel Pump Gear Number Of Teeth (Electronic)...2052
68...2052
Fuel Pump Gear Bore (Electronic)...2052
34...2052
Width Of Idler Gear And Bushing Assembly (Fitted)...2052
Flanged Bushing Inside Assembly (Fitted)...2052
Gear End Play (Production Limits)...2052
ENGINE SPECIFICATIONS (Cont'd)...2053
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses...2053
Oil Pump, Gear And Relief Valve...2053
End Play...2053
Inner Rotor...2053
Outer Rotor...2053
0.0010-0.0029 (0,025-0,076)...2053
Turbocharger...2053
Flywheel...2053
ENGINE SPECIFICATIONS (Cont'd)...2054
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses...2054
Water Pump And Thermostat...2054
180 F (82 C)...2054
170/185 F (77/85 C)...2054
198/208 F (92/98 C)...2054
0.35 (9,0)...2054
ENGINE SPECIFICATIONS (Cont'd)...2055
Engine Torque Component...2055
70...2055
95...2055
13...2055
18...2055
52...2055
70...2055
37...2055
50...2055
74...2055
100...2055
22...2055
18...2055
24...2055
18...2055
24...2055
22...2055
30...2055
16...2055
22...2055
7...2055
9...2055
7...2055
9...2055
20...2055
27...2055
MACHINE TORQUE SPECIFICATIONS...2057
221...2057
300...2057
FT.-LBS...2057
NM...2057
FT.-LBS...2057
NM...2057
FT.-LBS...2057
NM...2057
MACHINE TORQUE SPECIFICATIONS (CONT’D)...2058
FT.-LBS...2058
NM...2058
TORQUE SPECIFICATIONS FOR BOLTS...2059
Torque for General SAE Bolts...2059
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from Bobcat that have zinc phosphate coating are specified by the letter H following the part number...2059
INCH. LBS.(Nm)...2059
.250...2059
80-90 (9,0-10,2)...2059
110-120 (12,4-13,6)...2059
.3125...2059
180-200 (20,3-22,6)...2059
215-240 (24,2-27,1)...2059
FOOT LBS.(Nm)...2059
.375...2059
25-28 (34-38)...2059
35-40 (47-54)...2059
.4375...2059
40-45 (54-61)...2059
60-65 (81-88)...2059
.500...2059
65-70 (88-95)...2059
90-100 (122-136)...2059
.5625...2059
90-100 (122-136)...2059
125-140 (170-190)...2059
.625...2059
125-140 (170-190)...2059
175-190 (240-260)...2059
.750...2059
220-245 (300-330)...2059
300-330 (410-450)...2059
.875...2059
330-360 (450-490)...2059
475-525 (645-710)...2059
1.000...2059
475-525 (645-710)...2059
725-800 (985-1085)...2059
1.125...2059
650-720 (880-975)...2059
1050-1175 (1425-1600)...2059
1.250...2059
900-1000 (1200-1360)...2059
1475-1625 (2000-2200)...2059
1.375...2059
1200-1350 (1630-1830)...2059
2000-2200 (2720-2980)...2059
1.500...2059
1500-1650 (2040-2240)...2059
2600-2850 (3530-3870)...2059
1.625...2059
2000-2800 (2720-2980)...2059
3450-3800 (4680-5150)...2059
1.750...2059
2500-2750 (3390-3730)...2059
4300-4800 (5830-6500)...2059
1.875...2059
3150-3500 (4270-4750)...2059
5500-6100 (5830-6500)...2059
2.000...2059
3800-4200 (5150-5700)...2059
6500-7200 (8800-9800)...2059
TORQUE SPECIFICATIONS FOR BOLTS (Cont'd)...2060
Torque For General Metric Bolts...2060
Thread Size (Dia. x Pitch)...2060
Material...2060
Head Mark 4...2060
Head Mark 7...2060
Head Mark 10...2060
M 5 x 0.8...2060
3-4 ft.-lbs. (4-5 Nm)...2060
M 6 x 1.0...2060
6-7 ft.-lbs. (8-9 Nm)...2060
6-9 ft.-lbs. (8-12 Nm)...2060
M 8 x 1.25...2060
6-9 ft.-lbs. (8-12 Nm)...2060
11-16 ft.-lbs. (15-22 Nm)...2060
18-25 ft.-lbs. (24-34 Nm)...2060
M 10 x 1.25...2060
13-18 ft.-lbs. (18-24 Nm)...2060
22-30 ft.-lbs. (30-41 Nm)...2060
36-50 ft.-lbs. (49-68 Nm)...2060
M 12 x 1.25...2060
22-30 ft.-lbs. (30-41 Nm)...2060
40-54 ft.-lbs. (54-73 Nm)...2060
69-87 ft.-lbs. (94-118 Nm)...2060
M 14 x 1.5...2060
36-50 ft.-lbs. (49-68 Nm)...2060
58-80 ft.-lbs. (79-108 Nm)...2060
116-137 ft.-lbs. (157-186 Nm)...2060
HYDRAULIC CONNECTION SPECIFICATIONS...2061
Figure SPEC-50-15...2061
Figure SPEC-50-16...2061
HYDRAULIC CONNECTION SPECIFICATIONS (Cont'd)...2062
Figure SPEC-50-17...2062
5/8"...2062
5/16"...2062
1/2" - 20...2062
17 (23)...2062
2-1/2...2062
1...2062
11/16"...2062
3/8"...2062
9/16" - 18...2062
22 (30)...2062
2...2062
1...2062
7/8"...2062
1/2"...2062
3/4" - 16...2062
40 (54)...2062
2...2062
1...2062
1"...2062
5/8"...2062
7/8" - 14...2062
60 (81)...2062
1-1/2...2062
1...2062
1-1/4"...2062
3/4"...2062
1-1/16" - 12...2062
84 (114)...2062
1...2062
3/4...2062
1-3/8"...2062
1"...2062
1-5/16" - 12...2062
118 (160)...2062
3/4...2062
3/4...2062
HYDRAULIC CONNECTION SPECIFICATIONS (Cont'd)...2063
Figure SPEC-50-18...2063
Figure SPEC-50-19...2063
5/8"...2063
5/16"...2063
1/2" - 20...2063
17 (23)...2063
2-1/2...2063
1...2063
11/16"...2063
3/8"...2063
9/16" - 18...2063
22 (30)...2063
2...2063
1...2063
7/8"...2063
1/2"...2063
3/4" - 16...2063
40 (54)...2063
2...2063
1...2063
1"...2063
5/8"...2063
7/8" - 14...2063
60 (81)...2063
1-1/2...2063
1...2063
1-1/4"...2063
3/4"...2063
1-1/16" - 12...2063
84 (114)...2063
1...2063
3/4...2063
1-3/8"...2063
1"...2063
1-5/16" - 12...2063
118 (160)...2063
3/4...2063
3/4...2063
* If a torque wrench is used to tighten a new fitting to a used hose/tubeline...2063
* If a torque wrench is used to tighten a used fitting to a new hose/tubeline...2063
* If a torque wrench is used to tighten a new fitting to a new hose/tubeline...2063
** If using the hex flat tightening method to tighten a new fitting to a new hose/tubeline...2063
** If using the hex flat tightening method to tighten a new fitting to a used hose/tubeline...2063
*** If using the hex flat tightening method to tighten a used fitting to a new hose/tubeline...2063
HYDRAULIC CONNECTION SPECIFICATIONS (Cont'd)...2064
Figure SPEC-50-20...2064
Figure SPEC-50-21...2064
HYDRAULIC CONNECTION SPECIFICATIONS (Cont'd)...2065
Figure SPEC-50-22...2065
11/16"...2065
9/16" - 18...2065
15/16"...2065
3/4" - 16...2065
1-1/8"...2065
7/8" - 14...2065
1-1/4"...2065
1-1/16" - 12...2065
1-1/2"...2065
1-5/16" - 12...2065
Figure SPEC-50-23...2065
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...2067
CONVERSIONS...2069
CONVERSIONS (Cont’d)...2070
U.S. To Metric Conversion...2070
6986765 (2-10) - T3571, T3571L Telescopic Handler Service Manual...2071
MAINTENANCE SAFETY...2073
CONTENTS...2075
FOREWORD...2077
FOREWORD...2079
SAFETY INSTRUCTIONS...2081
FIRE PREVENTION...2082
Maintenance...2082
Operation...2082
Electrical...2082
Hydraulic System...2083
Fueling...2083
Starting...2083
Spark Arrester Exhaust System...2083
Welding And Grinding...2083
Fire Extinguishers...2083
SERIAL NUMBER LOCATION...2084
Telescopic Handler Serial Number...2084
Engine Serial Number...2084
Other Serial Numbers...2084
DELIVERY REPORT...2085
IDENTIFICATION OF THE TELESCOPIC HANDLER...2086
SAFETY AND MAINTENANCE...2087
LIFTING AND BLOCKING THE TELESCOPIC HANDLER...2089
Procedure...2089
OPERATOR CAB...2091
Emergency Exit...2091
Cab Door...2092
Cab Door Window...2092
TRANSPORTING THE TELESCOPIC HANDLER...2093
Loading And Unloading...2093
Fastening...2093
TOWING THE TELESCOPIC HANDLER...2095
Procedure...2095
SERVICE SCHEDULE...2097
AIR CLEANER SERVICE...2099
Replacing Filter Element...2099
ENGINE COOLING SYSTEM...2101
Cleaning The Cooling System...2101
Checking The Coolant Level...2101
Replacing The Coolant...2102
FUEL SYSTEM...2103
Fuel Specifications...2103
Filling The Fuel Tank...2103
Fuel Filter...2103
ENGINE LUBRICATION SYSTEM...2105
Checking Engine Oil...2105
Oil Chart...2105
Replacing Oil And Filter...2106
HYDRAULIC / HYDROSTATIC SYSTEM...2107
Checking And Adding Fluid...2107
Replacing Hydraulic / Hydrostatic Filter...2107
Replacing Hydraulic Fluid...2108
AXLES (FRONT AND REAR)...2109
Checking Oil Level (Planetary Carrier)...2109
Draining Oil (Planetary Carrier)...2109
Checking Oil Level (Rear Differential)...2110
Draining Oil (Rear Differential)...2110
Checking Oil Level (Front Differential)...2110
Draining Oil (Front Differential)...2111
LUBRICATION...2113
Procedure...2113
ATTACHMENT FRAME...2119
Inspection And Maintenance...2119
TYRE MAINTENANCE...2121
Wheel Nuts...2121
Tyre Mounting...2121
Tyre Rotation...2121
SPARK ARRESTER MUFFLER...2123
Cleaning...2123
APPROVED BOOM STOP...2125
Installing The Approved Boom Stop...2125
Removing The Approved Boom Stop...2125
ENGINE COVER...2127
Opening And Closing The Engine Cover...2127
HYDRAULIC SYSTEM...2129
HYDRAULIC SCHEMATICS...2133
HYDRAULIC SYSTEM INFORMATION...2136
Troubleshooting Chart...2139
Tightening Procedures...2140
LIFT CYLINDER...2142
Removal And Installation...2142
Parts Identification...2146
Disassembly...2147
Assembly...2152
BUCKET POSITIONING CYLINDER...2158
Removal And Installation...2158
Parts Identification...2161
Disassembly...2162
Assembly...2166
EXTENSION CYLINDER...2170
Cylinder Group Removal And Installation...2170
Upper Tubeline Removal...2172
Upper Tubeline Installation...2173
Extension Cylinder Removal And Installation...2175
Tubeline Tray Disassembly...2177
Tubeline Tray Assembly...2179
Parts Identification...2183
Disassembly...2184
Assembly...2188
TILT CYLINDER...2194
Removal And Installation...2194
Parts Identification...2195
Disassembly...2196
Assembly...2200
STEERING CYLINDER (FRONT)...2204
Removing The Steering Cylinder...2204
Installing The Steering Cylinder...2206
Disassembling The Steering Cylinder...2208
Assembling The Steering Cylinder...2210
STEERING CYLINDER (REAR)...2214
Removing The Steering Cylinder...2214
Installing The Steering Cylinder...2216
Disassembling The Steering Cylinder...2218
Assembling The Steering Cylinder...2219
DRIVE BOX...2224
Parts Identification...2224
Disassembly...2225
Assembly...2229
Special Tools...2232
MAIN RELIEF VALVE...2234
Testing And Adjustment...2234
Removal And Installation...2235
FRAME LEVELING CYLINDER...2236
Removal And Installation...2236
Parts Identification...2238
Disassembly...2239
Assembly...2244
STEERING MODE VALVE BLOCK...2250
Removal And Installation...2250
Parts Identification...2252
Disassembly...2253
Solenoid Testing...2255
Assembly...2255
BRAKE VALVE...2258
Removal And Installation...2258
Disassembly And Assembly...2259
GEAR PUMP...2262
Removal And Installation...2262
Parts Identification...2265
Disassembly And Assembly...2266
FAN MOTOR...2272
Removal And Installation...2272
Parts Identification...2276
Disassembly And Assembly...2277
HYDRAULIC RESERVOIR...2280
Removal And Installation...2280
STEERING VALVE...2282
Removal And Installation...2282
Parts Identification...2283
Disassembly...2284
Inspection...2287
Assembly...2287
HYDRAULIC CONTROL VALVE...2292
Troubleshooting Chart (Controllers)...2292
Telescoping Valve Section Troubleshooting...2293
Auxiliary Valve Section Troubleshooting...2297
Troubleshooting Chart (Control Valve)...2301
Removal And Installation...2302
Parts Identification...2306
Disassembly And Assembly...2307
End Housing Disassembly And Assembly...2308
Lifting Valve Section Disassembly And Assembly...2309
Tilting Valve Section Disassembly And Assembly...2314
Telescoping Valve Section Disassembly And Assembly...2319
Auxiliary/Frame Leveling Valve Section Disassembly And Assembly...2331
Inlet-Outlet Valve Section Disassembly And Assembly...2341
PORT RELIEF VALVES...2346
Adjustment Procedure...2346
FLOW CONTROL VALVE...2348
Removal And Installation...2348
JOYSTICK...2350
Removal And Installation...2350
PARKING BRAKE...2352
Pressure Switch Removal And Installation...2352
Pressure Switch Disassembly And Assembly...2354
Parking Brake Valve Removal And Installation...2355
Parking Brake Valve Disassembly And Assembly...2355
PRESSURE REDUCING VALVE...2358
Testing...2358
Removal And Installation...2359
Disassembly And Assembly...2360
ACCUMULATOR...2362
Removal And Installation...2362
TOW VALVE...2364
Removal And Installation...2364
Disassembly And Assembly...2365
HYDROSTATIC SYSTEM...2370
HYDROSTATIC SYSTEM INFORMATION...2372
Troubleshooting Chart...2372
Replenishing Valve Function...2373
Parts Identification...2375
Disassembly...2376
Assembly...2379
OIL COOLER...2382
Description...2382
HYDROSTATIC DRIVE MOTOR...2384
Removal And Installation...2384
Parts Identification...2385
Disassembly...2388
Inspection...2403
Assembly...2405
HYDROSTATIC PUMP...2422
Removal And Installation...2422
Parts Identification...2425
Disassembly...2430
Inspection...2442
Assembly...2446
DRIVE SYSTEM...2462
TROUBLESHOOTING...2464
Chart...2464
AXLE AND DIFFERENTIAL (FRONT)...2466
General Information...2466
Planetary Carrier Parts Identification...2466
Planetary Carrier Disassembly...2467
Steering Knuckle And Drive Axle Parts Identification...2472
Steering Knuckle Disassembly...2473
Drive Axle Disassembly...2475
Brake System Parts Identification...2477
Brake System Disassembly...2478
Differential Parts Identification...2482
Differential Disassembly...2483
Bevel Pinion Parts Identification...2488
Bevel Pinion Disassembly...2489
Bevel Pinion Assembly...2492
Differential Assembly...2501
Brake System Assembly...2506
Drive Axle Assembly...2512
Steering Knuckle Assembly...2514
Planetary Carrier Assembly...2517
Special Tools...2521
AXLE AND DIFFERENTIAL (REAR)...2522
General Information...2522
Planetary Carrier Parts Identification...2522
Steering Knuckle And Drive Axle Parts Identification...2528
Steering Knuckle Disassembly...2529
Differential And Bevel Pinion Parts Identification...2531
Differential Disassembly...2532
Bevel Pinion Disassembly...2536
Bevel Pinion Assembly...2539
Differential Assembly...2547
Steering Knuckle Assembly...2552
Planetary Carrier Assembly...2555
Special Tools...2559
FRONT AXLE...2560
Removal...2560
Installation...2567
AXLE TOE-IN...2574
Adjustment...2574
PARKING BRAKE...2576
Releasing The Brake For Towing...2576
Re-Activating The Brake...2577
STEERING ANGLE ADJUSTMENT...2578
Adjustment...2578
DRIVESHAFT...2580
Removal And Installation...2580
SERVICE BRAKE...2582
Description...2582
Bleeding The Brake Circuit...2582
REAR AXLE...2584
Removal...2584
Installation...2587
MAIN FRAME...2592
OPERATOR CAB (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...2594
Removal And Installation...2594
OPERATOR CAB (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...2602
Removal And Installation...2602
OPERATOR SEAT...2610
Removal And Installation...2610
BOOM ASSEMBLY...2612
Removal And Installation...2612
INNER BOOM...2616
Removal...2616
Installation...2618
WEAR PADS (FRONT)...2620
Removal And Installation...2620
WEAR PADS (REAR)...2622
Removal...2622
Installation...2622
ENGINE COVER...2624
Gas Cylinder Removal And Installation...2624
Removal And Installation...2624
AIR INTAKE COWLING...2626
Removal And Installation...2626
FUEL TANK...2628
Removal And Installation...2628
QUICK TACH...2632
Removal And Installation...2632
REAR WEIGHTS...2634
Removal And Installation...2634
FENDER...2636
Removal And Installation...2636
PIVOT LINK...2638
Removal And Installation...2638
DASH COVER / STEERING COLUMN COVER (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...2642
Removal And Installation...2642
DASH COVER / STEERING COLUMN COVER (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...2646
Removal And Installation...2646
JOYSTICK PANEL (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...2650
Removal And Installation...2650
JOYSTICK PANEL (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...2652
Removal And Installation...2652
ELECTRICAL SYSTEM AND ANALYSIS...2654
ELECTRICAL SYSTEM INFORMATION (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...2694
Troubleshooting Chart...2694
Description...2695
Fuses, Diodes And Relays...2695
ELECTRICAL SCHEMATICS (S/N 13000 & ABOVE)...2656
ELECTRICAL SCHEMATICS (S/N 12001 - 12999)...2668
ELECTRICAL SCHEMATICS (S/N 11001 - 11999)...2681
ELECTRICAL SYSTEM INFORMATION (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...2700
Troubleshooting Chart...2700
Description...2701
Fuses, Diodes And Relays...2701
BATTERY...2704
Removal And Installation...2704
Servicing...2705
Using A Booster Battery (Jump Starting)...2706
ALTERNATOR...2708
Removal And Installation...2708
Adjusting The Alternator Belt...2709
STARTER...2710
Removal And Installation...2710
Parts Identification...2711
Disassembly...2712
Inspection And Repair...2717
Assembly...2721
LIGHTS...2726
Rear Light Removal And Installation...2726
Front Light Removal And Installation...2727
TRAVEL / SIGNAL LEVER (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...2730
Removal And Installation...2730
TRAVEL / SIGNAL LEVER (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...2732
Removal And Installation...2732
INSTRUMENT PANEL...2734
Removal And Installation...2734
SWITCH PANEL (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...2736
Removal And Installation...2736
Parts description...2737
SWITCH PANEL (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...2740
Removal And Installation...2740
Parts description...2741
BRAKE LIGHT SWITCH...2744
Removal And Installation...2744
Adjustment...2744
FRONT WIPER MOTOR...2746
Removal And Installation...2746
TOP WIPER MOTOR...2750
Removal And Installation...2750
REAR WIPER MOTOR...2752
Removal And Installation...2752
PEDAL ASSEMBLY...2754
Removal And Installation...2754
Disassembly And Assembly...2755
INCHING SWITCH...2760
Removal And Installation...2760
Adjustment...2760
SERVICE SOFTWARE...2762
Connecting The Laptop Computer...2762
Entering The Service Software...2763
Monitor Screen...2764
Warnings Screen...2766
Calibrate Inch Pedal...2767
Calibrate Creep Potentiometer...2768
Program / Update Susmic Controller...2770
FRAME LEVEL SPEED SWITCH...2772
Description...2772
Removal...2772
Installation...2773
LONGITUDINAL STABILITY INDICATOR CALIBRATION...2774
Fitting The Sensor...2774
Calibration Procedure...2774
ENGINE SERVICE...2776
TROUBLESHOOTING...2780
Chart...2780
ENGINE SPEED CONTROL...2782
Removal And Installation...2782
MUFFLER...2784
Removal And Installation...2784
AIR CLEANER...2786
Housing Removal And Installation...2786
OIL COOLER / RADIATOR...2788
Removal And Installation...2788
Disassembly And Assembly...2791
ENGINE AND ENGINE MOUNTS...2794
Removal And Installation...2794
ENGINE COMPONENTS AND TESTING...2798
Fuel Injection Pump Removal...2798
Fuel Injection Pump Installation...2801
Fuel Injectors Removal And Installation...2804
Checking The Fuel Lift Pump...2806
Fuel Lift Pump Removal And Installation...2807
Compression Checking...2807
Glow Plugs Checking...2808
Glow Plugs Removal And Installation...2809
ENGINE TIMING...2810
Procedure...2810
ENGINE / HYDROSTAT ASSEMBLY...2812
Removal And Installation...2812
FLYWHEEL AND HOUSING...2826
Removal And Installation...2826
Ring Gear Removal...2829
Ring Gear Installation...2829
RECONDITIONING THE ENGINE...2830
Turbo Charger Troubleshooting...2830
Turbo Charger Description...2831
Turbo Charger Removal And Installation...2831
Exhaust Manifold Removal And Installation...2833
Fuel Injector Cover Removal And Installation...2833
Rocker Cover Removal And Installation...2834
Cylinder Head Removal...2835
Cylinder Head Inspection...2837
Cylinder Head Installation...2838
Rocker Shaft Disassembly And Assembly...2841
Valve Removal...2841
Valve Springs Checking...2842
Valve Depth Checking...2842
Valve Guides Checking...2843
Valve Guide Removal...2844
Valve Guide Installation...2844
Valves Checking...2845
Cutting A Valve Seat...2845
Valve Seat Assembly...2846
Changing Valve Springs (With Cylinder Head Installed)...2847
Valve Clearance Adjustment...2848
Timing Case And Drive Assembly Description...2849
Timing Cover Removal...2849
Timing Cover Installation...2849
Crankshaft Pulley Removal And Installation...2849
Front Oil Seal Removal And Installation...2849
Timing Case And Gear Removal...2850
Timing Case And Gear Installation...2851
Camshaft And Tappets Removal...2853
Camshaft And Tappets Installation...2854
Pistons And Connecting Rods Description...2855
Pistons And Connecting Rods Removal...2855
Pistons And Connecting Rods Disassembly...2857
Piston Ring End Gap...2857
Piston Ring Installation...2857
Piston Ring Groove Clearance...2858
Connecting Rod Inspection...2859
Connecting Rod Bushing Replacement...2859
Piston And Connecting Rod Assembly...2859
Piston And Connecting Rod Installation...2859
Checking Piston Height...2861
Crankshaft And Bearings Description...2861
Crankshaft And Bearings Removal...2861
Inspection Of Crankshaft And Bearings...2863
Crankshaft And Bearings Installation...2864
Rear Oil Seal Removal...2865
Rear Oil Seal Housing Positioning...2865
Rear Oil Seal Installation...2866
Checking Crankshaft End Play...2866
Cooling System Description...2867
Thermostat Removal and Installation...2868
Thermostat Testing...2869
Lubricating Oil Cooler Removal And Installation...2869
Water Pump Removal...2869
Water Pump Installation...2869
Engine Lubrication System Description...2870
Oil Filter Adapter Removal And Installation...2871
Oil Pan Removal And Installation...2871
Oil Screen And Pick-up Tube...2872
Oil Pump Removal...2872
Oil Pump Installation...2873
Oil Pump Disassembly And Assembly...2874
Oil Pressure Relief Valve Disassembly And Assembly...2874
Engine Block Description...2875
Engine Block Disassembly And Assembly...2875
Piston Cooling Jet Removal...2876
Piston Cooling Jet Installation...2876
Piston Cooling Jet Alignment...2876
Inspection...2876
Cylinder Liner Inspection...2877
Cylinder Liner Removal...2878
Cylinder Liner Installation...2879
HEATING, VENTILATION, AIR CONDITIONING...2880
AIR CONDITIONING SYSTEM FLOW...2882
Principles...2882
Chart...2883
COMPONENTS...2884
Identification...2884
SAFETY...2888
Safety Equipment...2888
REGULAR MAINTENANCE...2890
Filter Element Removal And Installation...2890
Compressor Drive Belt Inspection...2890
Cleaning The Condenser...2891
BASIC TROUBLESHOOTING...2892
Poor A/C Performance...2892
Compressor Drive Belt Inspection...2893
Checking The Electrical System...2894
GENERAL AIR CONDITIONING SERVICE GUIDELINES...2900
Compressor Oil...2900
Compressor Oil Check...2900
Component Replacement And Refrigeration Leaks...2902
SYSTEM TROUBLESHOOTING CHART...2904
TEMPERATURE / PRESSURE...2908
Chart...2908
AIR CONDITIONING SERVICE...2910
Chart...2910
SYSTEM CHARGING AND RECLAMATION...2912
Reclamation Procedure...2912
Charging Procedure With A Manifold Gauge Set...2915
Charging Procedure...2916
COMPRESSOR...2918
Removal And Installation...2918
Compressor Clutch Disassembly And Assembly...2919
CONDENSER (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...2924
Removal And Installation...2924
CONDENSER (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...2926
Removal And Installation...2926
RECEIVER / DRIER...2928
Removal And Installation...2928
PRESSURE SWITCH...2930
Removal And Installation...2930
EVAPORATOR / BLOWER UNIT (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...2932
Removal And Installation...2932
EVAPORATOR / BLOWER / HEATER UNIT (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...2934
Removal And Installation...2934
EXPANSION VALVE (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...2936
Removal And Installation...2936
EXPANSION VALVE (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...2938
Removal And Installation...2938
HEATER ASSEMBLY...2940
Removal And Installation...2940
Fan Removal And Installation...2941
Core Removal And Installation...2942
SPECIFICATIONS...2944
TELESCOPIC HANDLER SPECIFICATIONS...2946
Dimensional Specifications...2946
Performance Specifications...2947
Engine...2947
Fan Pump...2947
Controls...2947
Drive System...2948
Tyres...2948
Capacities...2948
Hydraulic System...2949
Electrical System...2949
Instrument Panel...2949
ENGINE SPECIFICATIONS...2950
General...2950
Cylinder Head...2950
Valve Guides...2950
Exhaust Valves...2951
Intake Valves...2951
Valve Springs...2951
Rocker Shaft, Rockers And Bushings...2952
Pistons And Piston Rings...2952
Connecting Rods And Bearings...2953
Crankshaft...2953
Crankshaft Re-Grind Data...2954
Main Bearings...2955
Thrust Washers...2955
Camshaft And Thrust Washer...2955
Cylinder Block...2955
Cylinder Liners...2956
Fuel Injection Pump...2956
Fuel Injectors...2956
Fuel Lift Pump...2956
Timing Case And Timing Gears...2957
Oil Pump, Gear And Relief Valve...2958
Turbocharger...2958
Flywheel...2958
Water Pump And Thermostat...2959
Engine Torque Component...2960
MACHINE TORQUE SPECIFICATIONS...2962
Axle...2962
Boom...2962
Drive Box...2962
Drive Motor...2962
Engine...2963
Hydraulic Pump...2963
TORQUE SPECIFICATIONS FOR BOLTS...2964
Torque for General SAE Bolts...2964
Torque For General Metric Bolts...2965
HYDRAULIC CONNECTION SPECIFICATIONS...2966
O-ring Face Seal Connection...2966
Straight Thread O-ring Fitting...2966
Tubelines And Hoses...2966
Port Seal Fitting...2967
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...2968
Specifications...2968
CONVERSIONS...2970
Decimal And Millimeter Equivalents...2970
U.S. To Metric Conversion...2970
ALPHABETICAL INDEX...2972
SERVICE MANUAL REVISION...2974
Revision No: T3571, T3571L - 1...2974
6986765 (8-12) - T3571, T3571L Telescopic Handler Service Manual...2976
MAINTENANCE SAFETY...2978
CONTENTS...2980
FOREWORD...2982
FOREWORD...2984
SAFETY INSTRUCTIONS...2986
FIRE PREVENTION...2987
Maintenance...2987
Operation...2987
Electrical...2987
Hydraulic System...2988
Fueling...2988
Starting...2988
Spark Arrester Exhaust System...2988
Welding And Grinding...2988
Fire Extinguishers...2988
SERIAL NUMBER LOCATION...2989
Telescopic Handler Serial Number...2989
Engine Serial Number...2989
Other Serial Numbers...2989
DELIVERY REPORT...2990
IDENTIFICATION OF THE TELESCOPIC HANDLER...2991
SAFETY & MAINTENANCE...2992
LIFTING AND BLOCKING THE TELESCOPIC HANDLER...2994
Procedure...2994
OPERATOR CAB (ROPS / FOPS)...2996
Cab Door...2997
Cab Door Window...2997
TRANSPORTING THE TELESCOPIC HANDLER ON A TRAILER...2998
Loading And Unloading...2998
Fastening...2998
TOWING THE TELESCOPIC HANDLER...3000
Procedure...3000
SERVICE SCHEDULE...3002
Chart...3002
AIR CLEANER SERVICE...3004
Replacing Filter Element...3004
ENGINE COOLING SYSTEM...3006
Cleaning...3006
Removing And Replacing The Coolant...3006
Checking Level...3008
FUEL SYSTEM...3010
Fuel Specifications...3010
Biodiesel Blend Fuel...3010
Filling The Fuel Tank...3011
Secondary Fuel Filter...3011
Primary Fuel Filter (Pre-Filter)...3012
Removing Air From The Fuel System...3013
ENGINE LUBRICATION SYSTEM...3014
Checking And Adding Engine Oil...3014
Engine Oil Chart...3014
Removing And Replacing Oil And Filter...3015
HYDRAULIC / HYDROSTATIC SYSTEM...3016
Checking And Adding Fluid...3016
Hydraulic / Hydrostatic Fluid Chart...3016
Removing And Replacing Hydraulic Fluid...3017
Removing And Replacing Hydraulic / Hydrostatic Filter...3018
Hydraulic Tank Breather...3018
ATTACHMENT CARRIER...3020
Inspection And Maintenance...3020
AXLES (FRONT AND REAR)...3022
Checking And Adding Oil (Planetary Carrier)...3022
Removing And Replacing Oil (Planetary Carrier)...3022
Checking And Adding Oil (Rear Differential)...3023
Removing And Replacing Oil (Rear Differential)...3023
Checking And Adding Oil (Front Differential)...3024
Removing And Replacing Oil (Front Differential)...3025
Checking And Adding Oil (Front Drop Box)...3026
Removing And Replacing Oil (Front Drop Box)...3026
LUBRICATING THE TELESCOPIC HANDLER...3028
Lubrication Locations...3028
TIRE MAINTENANCE...3034
Wheel Nuts...3034
Rotation...3034
Mounting...3034
APPROVED BOOM STOP...3036
Installing The Approved Boom Stop...3036
Removing The Approved Boom Stop...3036
ENGINE COVER...3038
Opening And Closing...3038
TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...3040
Storage...3040
Return To Service...3040
STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...3042
Procedure...3042
EMERGENCY EXIT...3044
Rear Window...3044
HYDRAULIC SYSTEM...3046
HYDRAULIC SCHEMATIC...3050
HYDRAULIC SYSTEM INFORMATION...3054
Glossary Of Hydraulic / Hydrostatic Symbols...3054
Troubleshooting Chart...3057
Tightening Procedures...3058
LIFT CYLINDER...3060
Removal And Installation...3060
Parts Identification...3064
Disassembly...3065
Assembly...3070
BUCKET POSITIONING CYLINDER...3076
Removal And Installation...3076
Parts Identification...3079
Disassembly...3080
Assembly...3084
EXTENSION CYLINDER...3088
Cylinder Group Removal And Installation...3088
Upper Tubeline Removal...3090
Upper Tubeline Installation...3091
Extension Cylinder Removal And Installation...3093
Tubeline Tray Disassembly...3095
Tubeline Tray Assembly...3097
Parts Identification...3101
Disassembly...3102
Assembly...3106
TILT CYLINDER...3112
Removal And Installation...3112
Parts Identification...3113
Disassembly...3114
Assembly...3118
STEERING CYLINDER (FRONT)...3122
Removal...3122
Installation...3124
Disassembly...3126
Assembly...3128
STEERING CYLINDER (REAR)...3132
Removal...3132
Installation...3134
Disassembly...3136
Assembly...3137
DRIVE BOX...3142
Parts Identification...3142
Disassembly...3143
Assembly...3147
Special Tools...3150
MAIN RELIEF VALVE...3152
Testing And Adjustment...3152
Removal And Installation...3153
QUICK-TACH CYLINDER...3154
Removal And Installation...3154
Parts Identification...3155
Disassembly...3156
Assembly...3159
FRAME LEVELING CYLINDER...3162
Removal And Installation...3162
Parts Identification...3164
Disassembly...3165
Assembly...3170
STEERING MODE VALVE BLOCK...3176
Removal And Installation...3176
Parts Identification...3178
Disassembly...3179
Solenoid Testing...3181
Assembly...3181
BRAKE VALVE...3184
Removal And Installation...3184
Disassembly And Assembly...3185
GEAR PUMP...3188
Removal And Installation...3188
Parts Identification...3191
Disassembly And Assembly...3192
FAN MOTOR...3198
Removal And Installation...3198
Parts Identification...3202
Disassembly And Assembly...3203
HYDRAULIC FLUID RESERVOIR...3206
Removal And Installation...3206
STEERING VALVE...3208
Removal And Installation...3208
Parts Identification...3209
Disassembly...3210
Inspection...3213
Assembly...3213
HYDRAULIC CONTROL VALVE...3218
Troubleshooting Chart (Controllers)...3218
Telescoping Valve Section Troubleshooting...3219
Auxiliary Valve Section Troubleshooting...3223
Troubleshooting Chart (Control Valve)...3227
Removal And Installation...3228
Parts Identification...3232
Disassembly And Assembly...3233
End Housing Disassembly And Assembly...3234
Lifting Valve Section Disassembly And Assembly...3235
Tilting Valve Section Disassembly And Assembly...3240
Telescoping Valve Section Disassembly And Assembly...3245
Auxiliary / Frame Leveling Valve Section Disassembly And Assembly...3257
Inlet-Outlet Valve Section Disassembly And Assembly...3267
PORT RELIEF VALVES...3272
Adjustment Procedure...3272
FLOW CONTROL VALVE...3274
Removal And Installation...3274
JOYSTICK...3276
Removal And Installation...3276
PARKING BRAKE...3278
Pressure Switch Removal And Installation...3278
Pressure Switch Disassembly And Assembly...3280
Parking Brake Valve Removal And Installation...3281
Parking Brake Valve Disassembly And Assembly...3281
PRESSURE REDUCING VALVE...3284
Testing...3284
Removal And Installation...3285
Disassembly And Assembly...3286
ACCUMULATOR...3288
Removal And Installation...3288
TOW VALVE...3290
Removal And Installation...3290
Disassembly And Assembly...3291
HYDROSTATIC SYSTEM...3296
HYDROSTATIC SYSTEM INFORMATION...3298
Troubleshooting Chart...3298
Replenishing Valve Function...3299
OIL COOLER...3300
Description...3300
HYDROSTATIC DRIVE MOTOR...3302
Removal And Installation...3302
Parts Identification...3303
Disassembly...3306
Inspection...3321
Assembly...3323
HYDROSTATIC PUMP...3340
Removal And Installation...3340
Parts Identification...3343
Disassembly...3348
Inspection...3360
Assembly...3364
DRIVE SYSTEM...3380
TROUBLESHOOTING...3382
Chart...3382
AXLE AND DIFFERENTIAL (FRONT)...3384
General Information...3384
Planetary Carrier Parts Identification...3384
Planetary Carrier Disassembly...3385
Steering Knuckle And Drive Axle Parts Identification...3390
Steering Knuckle Disassembly...3391
Drive Axle Disassembly...3393
Brake System Parts Identification...3395
Brake System Disassembly...3396
Differential Parts Identification...3400
Differential Disassembly...3401
Bevel Pinion Parts Identification...3406
Bevel Pinion Disassembly...3407
Bevel Pinion Assembly...3410
Differential Assembly...3419
Brake System Assembly...3424
Drive Axle Assembly...3430
Steering Knuckle Assembly...3432
Planetary Carrier Assembly...3435
Special Tools...3439
AXLE AND DIFFERENTIAL (REAR)...3440
General Information...3440
Planetary Carrier Parts Identification...3440
Steering Knuckle And Drive Axle Parts Identification...3446
Steering Knuckle Disassembly...3447
Differential And Bevel Pinion Parts Identification...3449
Differential Disassembly...3450
Bevel Pinion Disassembly...3454
Bevel Pinion Assembly...3457
Differential Assembly...3465
Steering Knuckle Assembly...3470
Planetary Carrier Assembly...3473
Special Tools...3477
FRONT AXLE...3478
Removal...3478
Installation...3485
AXLE TOE-IN...3492
Adjustment...3492
PARKING BRAKE...3494
Releasing The Brake For Towing...3494
Re-Activating The Brake...3495
STEERING ANGLE ADJUSTMENT...3496
Adjustment...3496
DRIVE SHAFT...3498
Removal And Installation...3498
SERVICE BRAKE...3500
Description...3500
Bleeding The Brake Circuit...3500
REAR AXLE...3502
Removal...3502
Installation...3505
MAINFRAME...3510
OPERATOR CAB (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...3512
Removal And Installation...3512
OPERATOR CAB (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...3520
Removal And Installation...3520
OPERATOR SEAT...3528
Removal And Installation...3528
BOOM ASSEMBLY...3530
Removal And Installation...3530
INNER BOOM...3534
Removal...3534
Installation...3536
WEAR PADS (FRONT)...3538
Removal And Installation...3538
WEAR PADS (REAR)...3540
Removal...3540
Installation...3540
ENGINE COVER...3542
Gas Cylinder Removal And Installation...3542
Removal And Installation...3542
AIR INTAKE COWLING...3544
Removal And Installation...3544
FUEL TANK...3546
Removal And Installation...3546
QUICK-TACH...3550
Removal And Installation...3550
REAR WEIGHTS...3552
Removal And Installation...3552
FENDER...3554
Removal And Installation...3554
PIVOT LINK...3556
Removal And Installation...3556
JOYSTICK PANEL (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...3560
Removal And Installation...3560
JOYSTICK PANEL (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...3562
Removal And Installation...3562
DASH COVER / STEERING COLUMN COVER (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...3564
Removal And Installation...3564
DASH COVER / STEERING COLUMN COVER (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...3568
Removal And Installation...3568
ELECTRICAL SYSTEM AND ANALYSIS...3572
ELECTRICAL SCHEMATIC...3574
ELECTRICAL SYSTEM INFORMATION (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...3622
Troubleshooting Chart...3622
Description...3624
Fuses, Diodes And Relay Location / Identification...3624
ELECTRICAL SYSTEM INFORMATION (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...3628
Troubleshooting Chart...3628
Description...3629
Fuses, Diode And Relay Location / Identification...3629
BATTERY...3632
Removal And Installation...3632
Servicing...3633
Using A Booster Battery (Jump Starting)...3634
ALTERNATOR...3636
Removal And Installation...3636
Belt Adjusting...3637
Belt Replacement...3637
STARTER...3638
Testing...3638
Removal And Installation...3638
LIGHTS...3640
Rear Light Removal And Installation...3640
Front Light Removal And Installation...3641
TRAVEL / SIGNAL LEVER (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...3644
Removal And Installation...3644
TRAVEL / SIGNAL LEVER (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...3646
Removal And Installation...3646
INSTRUMENT PANEL...3648
Removal And Installation...3648
SWITCH PANEL (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...3650
Removal And Installation...3650
Parts description...3651
SWITCH PANEL (S/N A8HF13000 - 14999, S/N A8H613000 - 14999)...3654
Removal And Installation...3654
SWITCH PANEL (S/N A8HF15000 & ABOVE, S/N A8H615000 & ABOVE)...3656
Removal And Installation...3656
BRAKE LIGHT SWITCH...3658
Removal And Installation...3658
Adjustment...3658
WIPER MOTOR (FRONT)...3660
Removal And Installation...3660
WIPER MOTOR (TOP)...3664
Removal And Installation...3664
WIPER MOTOR (REAR)...3666
Removal And Installation...3666
PEDAL ASSEMBLY...3668
Removal And Installation...3668
Disassembly And Assembly...3669
INCHING SWITCH...3674
Removal And Installation...3674
Adjustment...3674
SERVICE SOFTWARE...3676
Connecting The Laptop Computer...3676
Entering The Service Software...3677
Monitor Screen...3678
Warnings Screen...3680
Calibrate Inch Pedal...3681
Calibrate Creep Potentiometer...3682
Program / Update Susmic Controller...3684
FRAME LEVEL SPEED SWITCH...3686
Description...3686
Removal...3686
Installation...3687
LONGITUDINAL STABILITY INDICATOR CALIBRATION (S/N A8HF11001-14999, S/N A8H611001-14999)...3688
Fitting The Sensor...3688
Calibration Procedure...3688
LLMI / LLMC SYSTEM (S/N A8HF15000 & ABOVE, S/N A8H615000 & ABOVE)...3690
System Calibration...3690
Calibration Test...3692
System Failure Reports...3693
System Components Identification...3697
LLMS Removal...3699
LLMS Installation...3700
LLMC Controller Removal...3702
LLMC Controller Installation...3705
ENGINE SERVICE...3708
ENGINE INFORMATION...3712
Specifications...3712
Troubleshooting...3723
ENGINE SPEED CONTROL...3726
Removal And Installation...3726
MUFFLER...3728
Removal And Installation...3728
AIR CLEANER...3730
Housing Removal And Installation...3730
OIL COOLER / RADIATOR...3732
Removal And Installation...3732
Disassembly And Assembly...3735
ENGINE AND ENGINE MOUNTS...3738
Removal And Installation...3738
ENGINE COMPONENTS AND TESTING...3742
Fuel Injection Pump Removal...3742
Fuel Injection Pump Installation...3745
Fuel Injector Removal And Installation...3748
Checking The Fuel Lift Pump...3751
Fuel Lift Pump Removal And Installation...3751
Compression Checking...3752
Glow Plug Checking...3753
Glow Plugs Removal And Installation...3754
ENGINE TIMING...3756
Procedure...3756
ENGINE / HYDROSTAT ASSEMBLY...3758
Removal And Installation...3758
FLYWHEEL AND HOUSING...3772
Removal And Installation...3772
Ring Gear Removal...3775
Ring Gear Installation...3775
RECONDITIONING THE ENGINE...3776
Turbocharger Troubleshooting...3776
Turbocharger Description...3777
Turbocharger Removal And Installation...3777
Exhaust Manifold Removal And Installation...3779
Fuel Injector Cover Removal And Installation...3779
Rocker Cover Removal And Installation...3780
Cylinder Head Removal...3781
Cylinder Head Inspection...3783
Cylinder Head Installation...3784
Rocker Shaft Disassembly And Assembly...3787
Valve Removal...3787
Valve Springs Checking...3788
Valve Depth Checking...3788
Valve Guides Checking...3789
Valve Guide Removal...3790
Valve Guide Installation...3790
Valves Checking...3791
Cutting Valve Seat...3791
Valve Seat Assembly...3792
Changing Valve Springs (With Cylinder Head Installed)...3793
Valve Clearance Adjustment...3794
Timing Case And Drive Assembly Description...3795
Timing Cover Removal...3795
Timing Cover Installation...3795
Crankshaft Pulley Removal And Installation...3795
Front Oil Seal Removal And Installation...3795
Timing Case And Gear Removal...3796
Timing Case And Gear Installation...3797
Camshaft And Tappets Removal...3799
Camshaft And Tappets Installation...3800
Pistons And Connecting Rods Description...3801
Pistons And Connecting Rods Removal...3801
Pistons And Connecting Rods Disassembly...3803
Piston Ring End Gap...3803
Piston Ring Installation...3803
Piston Ring Groove Clearance...3804
Connecting Rod Inspection...3805
Connecting Rod Bushing Replacement...3805
Piston And Connecting Rod Assembly...3805
Piston And Connecting Rod Installation...3805
Checking Piston Height...3807
Crankshaft And Bearings Description...3807
Crankshaft And Bearings Removal...3807
Inspection Of Crankshaft And Bearings...3809
Crankshaft And Bearings Installation...3810
Rear Oil Seal Removal...3811
Rear Oil Seal Housing Positioning...3811
Rear Oil Seal Installation...3812
Checking Crankshaft End Play...3813
Cooling System Description...3813
Thermostat Removal and Installation...3814
Thermostat Testing...3815
Lubricating Oil Cooler Removal And Installation...3815
Water Pump Removal...3815
Water Pump Installation...3815
Engine Lubrication System Description...3816
Oil Filter Adapter Removal And Installation...3817
Oil Pan Removal And Installation...3817
Oil Screen And Pick-Up Tube...3818
Oil Pump Removal...3818
Oil Pump Removal (Cont'd)...3819
Oil Pump Installation...3819
Oil Pump Installation (Cont'd)...3820
Oil Pump Disassembly And Assembly...3820
Oil Pump Disassembly And Assembly (Cont'd)...3821
Oil Pressure Relief Valve Disassembly And Assembly...3821
Engine Block Description...3822
Engine Block Disassembly And Assembly...3822
Piston Cooling Jet Removal...3823
Piston Cooling Jet Installation...3823
Piston Cooling Jet Alignment...3823
Inspection...3823
Cylinder Liner Inspection...3824
Cylinder Liner Removal...3825
Cylinder Liner Installation...3826
HEATING, VENTILATION AND AIR CONDITIONING...3828
AIR CONDITIONING SYSTEM FLOW...3830
Description...3830
Chart...3831
Components...3832
Safety Equipment...3835
REGULAR MAINTENANCE...3836
Filters...3836
Compressor And Alternator Drive Belt Inspection...3836
Cleaning The Condenser...3837
Air Conditioning Lubrication...3837
Air Conditioning Service Chart...3838
TROUBLESHOOTING...3840
Blower Motor Does Not Operate...3840
Blower Motor Operates Normally, But Air Flow Is Insufficient...3840
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...3840
The Compressor Does Not Operate At All, Or Operates Improperly...3840
Gauge Pressure Related Troubleshooting...3841
Gauge Pressure Related Troubleshooting (Cont’d)...3842
Troubleshooting Tree...3843
Temperature / Pressure Chart...3847
Poor A/C Performance...3848
HVAC Repair And Leaks...3849
Electrical System...3850
SYSTEM CHARGING AND RECLAMATION...3856
Reclamation Procedure...3856
Charging Procedure With A Manifold Gauge Set...3859
Charging Procedure...3860
COMPRESSOR...3862
Removal And Installation...3862
Oil Check...3863
Compressor Clutch Disassembly And Assembly...3865
Oil...3868
CONDENSER (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...3870
Removal And Installation...3870
CONDENSER (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...3872
Removal And Installation...3872
RECEIVER / DRIER...3874
Removal And Installation...3874
PRESSURE SWITCH...3876
Removal And Installation...3876
EVAPORATOR / BLOWER UNIT (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...3878
Removal And Installation...3878
EVAPORATOR / BLOWER UNIT (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...3880
Removal And Installation...3880
EXPANSION VALVE (S/N A8HF12999 & BELOW, S/N A8H612999 & BELOW)...3882
Removal And Installation...3882
EXPANSION VALVE (S/N A8HF13000 & ABOVE, S/N A8H613000 & ABOVE)...3884
Removal And Installation...3884
HEATER ASSEMBLY...3886
Removal And Installation...3886
Fan Removal And Installation...3887
Core Removal And Installation...3888
SPECIFICATIONS...3890
(T3571) TELESCOPIC HANDLER SPECIFICATIONS...3892
Machine Dimensions...3892
Performance...3893
Weights...3893
Engine...3893
Controls...3894
Drive System...3894
Traction...3894
Steering...3894
Brakes...3894
Fluid Capacities...3895
Hydraulic System...3895
Electrical System...3895
Instrument Panel...3896
Environmental...3896
Temperature Range...3896
(T3571L) TELESCOPIC HANDLER SPECIFICATIONS...3898
Dimensional Specifications...3898
Performance Specifications...3899
Weights...3899
Engine...3899
Controls...3900
Drive System...3900
Traction...3900
Steering...3900
Brakes...3900
Fluid Capacities...3901
Hydraulic System...3901
Electrical...3901
Instruments...3902
Environmental...3902
Temperature Range...3902
MACHINE TORQUE SPECIFICATIONS...3904
Axle...3904
Boom...3904
Drive Box...3904
Drive Motor...3904
Engine...3905
Hydraulic Pump...3905
TORQUE SPECIFICATIONS FOR BOLTS...3906
Torque for General SAE Bolts...3906
Torque For General Metric Bolts...3907
HYDRAULIC CONNECTION SPECIFICATIONS...3908
O-ring Face Seal Connection...3908
Straight Thread O-ring Fitting...3908
Tubelines And Hoses...3908
Port Seal Fitting...3909
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS...3910
Specifications...3910
CONVERSIONS...3912
Decimal And Millimeter Equivalents...3912
U.S. To Metric Conversion...3912
ALPHABETICAL INDEX...3914
SERVICE MANUAL REVISION...3918
Revision No: T3571, T3571L - 1...3918
Revision No: T3571, T3571L - 2...3920
Revision No: T3571, T3571L - 3...3922
6989559 (2-10) - T3571(L) Telescopic Handler Operation & Maintenance Manual...3926
CONTENTS...3930
FOREWORD...3932
DECLARATION OF CONFORMITY...3934
Model T3571...3934
Model T3571L...3935
BOBCAT COMPANY IS IS0 9001 CERTIFIED...3936
REGULAR MAINTENANCE ITEMS...3936
Parts...3936
Lubricants, Fuel and Fluids...3937
SERIAL NUMBER LOCATION...3938
Telescopic Handler Serial Number...3938
Engine Serial Number...3938
Other Serial Numbers...3938
DELIVERY REPORT...3939
BOBCAT telescopic handler IDENTIFICATION...3940
FEATURES, ACCESSORIES AND ATTACHMENTS...3941
Standard Items...3941
Options And Accessories...3941
Available Tyres...3941
Attachments...3941
Windscreen Grill...3942
Windscreen Grill Inspection And Maintenance...3942
SAFETY & TRAINING RESOURCES...3944
SAFETY INSTRUCTIONS...3946
Before Operation...3946
Safe Operation Is The Operator’s Responsibility...3947
Safe Operation Needs A Qualified Operator...3947
Avoid Silica Dust...3948
FIRE PREVENTION...3948
Maintenance...3948
Operation...3948
Electrical...3948
Hydraulic System...3949
Fueling...3949
Starting...3949
Spark Arrester Exhaust System...3949
Welding And Grinding...3949
Fire Extinguishers...3949
PUBLICATIONS AND TRAINING RESOURCES...3950
MACHINE SIGNS (DECALS)...3951
No-Text Safety Signs...3954
LOAD CHARTS...3958
CHARTS FOR T3571 MACHINE...3960
charts for t3571l machine...3963
OPERATING INSTRUCTIONS...3966
OPERATOR CONTROLS IDENTIFICATION...3968
Operator Components...3968
Travel Direction And Two-Speed Control...3968
Steering Wheel...3969
Direction Signal...3969
Front Wiper/Washer/Headlight Dimmer...3969
Horn...3969
Steering Wheel Tilt Adjustment...3970
Longitudinal Stability Indicator / AMA System...3970
Centre Instrument Panel...3971
Right Instrument And Indicator Panel...3972
Left Instrument Panel...3974
Heater / Air Conditioning Controls (If Equipped)...3974
Rear Console...3975
Accelerator Pedal...3975
Brake Pedal And Inching Control...3975
Frame Level Switch (If Equipped)...3976
OPERATOR CAB (ROPS / FOPS)...3977
Description...3977
Cab Door...3977
Cab Door Window...3978
STEERING MODE SELECTION...3979
Steering Controls...3979
PARKING BRAKE...3980
Operation...3980
EMERGENCY EXIT...3980
Rear Window...3980
BACK-UP ALARM SYSTEM (IF EQUIPPED)...3981
Description...3981
Operation...3981
DRIVING AND STEERING THE TELESCOPIC HANDLER...3982
4-Wheel Steering Mode...3982
Stopping The Telescopic Handler (4-Wheel Steering Mode)...3983
2-Wheel Steering Mode...3984
Stopping The Telescopic Handler (2-Wheel Steering Mode)...3985
Crab Steering Mode...3986
Stopping The Telescopic Handler (Crab Steering Mode)...3987
CREEP MODE OPERATION...3988
Description...3988
Operation...3988
HYDRAULIC CONTROLS...3989
Hydraulic Control Lever (Joystick)...3989
Auxiliary Hydraulic Release...3990
DAILY INSPECTION...3991
Daily Inspection And Maintenance...3991
PRE-STARTING PROCEDURE...3993
Entering The Telescopic Handler...3993
Operation & Maintenance Manual Location...3993
Seat Adjustment...3994
Seat Belt Adjustment...3994
Panel Switch Position...3995
STARTING THE ENGINE...3996
Cold Temperature Starting...3997
Warming The Hydraulic / Hydrostatic System...3997
MONITORING THE DISPLAY PANELS...3998
Panel...3998
STOPPING THE ENGINE AND LEAVING THE TELESCOPIC HANDLER...3998
Procedure...3998
ATTACHMENTS...3999
Installing And Removing The Attachment (Manual Locking)...3999
Installing And Removing The Attachment (Hydraulic Locking) (Optional)...4000
OPERATING PROCEDURE...4002
Aggravating Movements Arrester System (AMA)...4002
Deactivation Switch Key for the Aggravating Movements Arrester (AMA) System...4002
Inspecting The Work Area...4003
Basic Operating Instructions...4003
Operating With A Full Bucket...4004
Operating With An Empty Bucket...4004
Filling And Emptying The Bucket...4005
Digging And Filling A Hole...4006
Raising A Load And Extending The Boom...4007
Using Frame Levelling (If Equipped)...4008
Load Capacity Charts...4008
TOWING THE telescopic handler...4009
Procedure...4009
LIFTING THE telescopic handler...4011
TRANSPORTING THE telescopic handler...4012
Loading And Unloading...4012
Fastening...4012
PREVENTIVE MAINTENANCE...4014
SERVICE SCHEDULE...4018
SEAT BELT...4019
Inspection And Maintenance...4019
APPROVED BOOM STOP (IF EQUIPPED)...4020
Installing The Approved Boom Stop...4020
Removing The Approved Boom Stop...4020
BACK-UP ALARM SYSTEM (IF EQUIPPED)...4021
Description...4021
Inspecting...4021
ENGINE COVER...4021
Opening And Closing...4021
Heating, VENTILATION AND AIR CONDITIONING System (HVAC)...4022
Cleaning And Maintenance...4022
Filters...4022
Condenser...4022
Air Conditioning Lubrication...4022
Troubleshooting...4022
AIR CLEANER SERVICE...4023
Replacing Filters...4023
FUEL SYSTEM...4025
Fuel Specifications...4025
Biodiesel Blend Fuel...4025
Filling The Fuel Tank...4025
Secondary Fuel Filter...4026
Primary Fuel Filter (Pre-Filter)...4026
Removing Air From The Fuel System...4027
ENGINE LUBRICATION SYSTEM...4028
Checking And Adding Engine Oil...4028
Engine Oil Chart...4028
Removing And Replacing Oil And Filter...4029
ENGINE COOLING SYSTEM...4030
Cleaning...4030
Removing And Replacing The Coolant...4031
Checking Level...4032
ELECTRICAL SYSTEM...4032
Description...4032
Fuses, Diode And Relay Location / Identification...4033
Battery Maintenance...4035
Using A Booster Battery (Jump Starting)...4036
Removing And Installing Battery...4037
Battery Disconnect Switch...4039
HYDRAULIC/HYDROSTATIC SYSTEM...4040
Checking And Adding Fluid...4040
Hydraulic / Hydrostatic Fluid Chart...4040
Removing And Replacing Hydraulic Fluid...4041
Removing And Replacing Hydraulic/Hydrostatic Filter...4042
Hydraulic Tank Breather...4042
AXLES (FRONT AND REAR)...4043
Checking And Adding Oil (Planetary Carrier)...4043
Removing And Replacing Oil (Planetary Carrier)...4043
Checking And Adding Oil (Rear Differential)...4044
Removing And Replacing Oil (Rear Differential)...4044
Checking And Adding Oil (Front Differential)...4045
Removing And Replacing Oil (Front Differential)...4046
Checking And Adding Oil (Front Drop Box)...4047
Removing And Replacing Oil (Front Drop Box)...4047
ALTERNATOR BELT...4048
Belt Adjusting...4048
Belt Replacement...4048
TYRE MAINTENANCE...4049
Wheel Nuts...4049
Tyre Mounting...4049
Tyre Rotation...4049
Tyre Pressure...4049
LUBRICATING THE TELESCOPIC HANDLER...4050
Lubrication Locations...4050
PIVOT PIN...4054
Inspection And Maintenance...4054
ATTACHMENT FRAME...4055
Inspection And Maintenance...4055
TELESCOPIC HANDLER STORAGE AND RETURN TO SERVICE...4056
Storage...4056
Return To Service...4056
SPECIFICATIONS...4058
(T3571) TELESCOPIC HANDLER SPECIFICATIONS...4060
Dimensional Specifications...4060
Performance Specifications...4061
Weights...4061
Engine...4061
Controls...4062
Drive System...4062
Traction...4062
Steering...4062
Brakes...4062
Fluid Capacities...4063
Hydraulic System...4063
Electrical...4063
Instruments...4064
Environmental...4064
Temperature Range...4064
(T3571L) TELESCOPIC HANDLER SPECIFICATIONS...4066
Dimensional Specifications...4066
Performance Specifications...4067
Weights...4067
Engine...4067
Controls...4068
Drive System...4068
Traction...4068
Steering...4068
Brakes...4068
Fluid Capacities...4069
Hydraulic System...4069
Electrical...4069
Instruments...4070
Environmental...4070
Temperature Range...4070
WARRANTY...4072
WARRANTY...4074
ALPHABETICAL INDEX...4076
Bobcat T3571, T3571L Telescopic Handlers Repair Service Manuals
