Bobcat S66 B51U11001 & Up 7400113 (Preview)
MAINTENANCE SAFETY
CONTENTS
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrester Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATIONS
Machine Serial Number Location
Engine Serial Number Location
DELIVERY REPORT
LOADER IDENTIFICATION
Front View
Rear View
SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE LOADER
Procedure
LIFT ARM SUPPORT
Lift Arm Support Description
Installing Lift Arm Support
Removing Lift Arm Support
OPERATOR CAB
Inspecting Operator Cab
Cab Door Sensor Theory Of Operation
Raising Operator Cab
Lowering Operator Cab
Clear Side Enclosed Cab Option
Inspecting And Maintaining Clear Side Enclosed Cab Option
Special Applications Kit
Inspecting And Maintaining Special Applications Kit
Forestry Door And Window Kit
Inspecting And Maintaining Forestry Door And Window Kit
TRANSPORTING THE MACHINE
Loading And Unloading Machine
Fastening Machine To Transport Vehicle
TOWING THE LOADER
Procedure
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666
Description
Remote Start Tool (Service Tool) – 7022042
Loader Service Tool Harness – 6689747
Computer Service Tool Harness – 6689746
Remote Start Procedure
SERVICE SCHEDULE
Maintenance Intervals
Service Schedule Symbols
ENGINE AIR CLEANER
Replacing Engine Air Filter Element (Outer)
Replacing Engine Air Filter Element (Inner)
ENGINE COOLING SYSTEM
Cleaning Engine Cooling System
Checking And Adding Coolant
Replacing Coolant
FUEL SYSTEM
Fuel Specifications
Biodiesel Blend Fuel
Filling The Fuel Tank
Removing Water From Main Fuel Filter
Replacing Fuel Pre-Filter
Replacing Main Fuel Filter
Replacing Fuel Tank Vent Filter
DIESEL PARTICULATE FILTER (DPF) SYSTEM
Description
DPF Service Regeneration
DPF Cleaning
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil Chart
Replacing Engine Oil And Filter
HYDRAULIC SYSTEM
Checking And Adding Hydraulic Fluid (Earlier Models)
Checking And Adding Hydraulic Fluid (Later Models)
Hydraulic Fluid Chart
Replacing Hydraulic Fluid
Replacing Main Hydraulic Filter
Replacing Hydraulic Charge Filter
Replacing Hydraulic Reservoir Vent Filter
FINAL DRIVE TRANSMISSION (CHAINCASES)
Checking And Adding Chaincase Fluid
Replacing Chaincase Fluid
BOB-TACH (HAND LEVER)
Inspecting And Maintaining Hand Lever Bob-Tach
BOB-TACH (POWER)
Inspecting And Maintaining Power Bob-Tach
MACHINE LUBRICATION
Lubricating Grease Fittings
TYRE MAINTENANCE
Checking Wheel Nut Torque
Rotating Tyres
Mounting Tyres
PIVOT PINS
Checking Pivot Pin Torque
LOADER STORAGE AND RETURN TO SERVICE
Loader Extended Storage Procedure
Loader Return To Service Procedure
STOPPING THE ENGINE AND LEAVING THE MACHINE
Procedure
EMERGENCY EXITS
Removing Rear Window With Latches
Removing Rear Window With Rubber Cord
Removing Rear Window With Latches From Outside Loader
Removing Rear Window With Rubber Cord From Outside Loader
Removing Front Door
Front Door Reassembly
SEAT BELT
Inspection And Maintenance
HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
MANUAL WITH NO OPTIONS
S/N B51U110011 AND ABOVE
MANUAL WITH ALL OPTIONS
S/N B51U110011 AND ABOVE
SJC WITH NO OPTIONS
S/N B51U110011 AND ABOVE
SJC WITH ALL OPTIONS
S/N B51U110011 AND ABOVE
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic Symbols
Troubleshooting
CYLINDER (LIFT)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (TILT)
Testing
Removal And Installation
Base End Pivot Pin Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (BOB-TACH)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (BOB-TACH) (LATER MODELS)
Testing
Removal And Installation
Disassembly
Assembly
MAIN RELIEF VALVE
Description
Testing
Main Relief Valve Removal And Installation
HYDRAULIC CONTROL VALVE
Description
Removal And Installation
Actuator Removal And Installation
Identification Chart
Lift Load Check Valve Removal And Installation
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)
Port Relief Valve Removal And Installation
Plug Removal And Installation
End Cap Block Removal And Installation
Lift Spool Removal And Installation
Lift Spool Disassembly And Assembly
Tilt Spool Removal And Installation
Tilt Spool Disassembly And Assembly
Auxiliary Spool Removal And Installation
Solenoid Removal And Installation
BICS™ Lock Valve Removal And Installation
Lift Arm Bypass Orifice Removal And Installation
Main Relief Valve Removal And Installation
Screen Fitting Removal And Installation
LIFT ARM BYPASS CONTROL VALVE
Description
Testing
Removal And Installation
Bracket Removal And Installation
Disassembly And Assembly
HYDRAULIC PUMP (STANDARD FLOW)
Description
Pump Test At Quick Couplers
Direct Pump Test (Standard Section)
Direct Pump Test (Charge Section)
Removal And Installation
Hydraulic Pump Startup
Parts Identification
Disassembly And Assembly
HYDRAULIC PUMP (HIGH FLOW)
Description
Direct Pump Test (Standard Section)
Direct Pump Test (Charge Section)
Direct Pump Test (High Flow Section)
High Flow Relief Valve Adjustment
High Flow Relief Valve Removal And Installation
Solenoid Removal And Installation
Removal And Installation
Hydraulic Pump Startup
Parts Identification
Disassembly And Assembly
HYDRAULIC FILTERS
Description
Main Filter Housing Removal And Installation
HYDRAULIC FLUID RESERVOIR
Description
Removal And Installation
OIL COOLER
Description
Removal And Installation
BUCKET POSITION SENSORS
Description
Removal And Installation
REAR AUXILIARY DIVERTER VALVE
Description
Removal And Installation
Disassembly And Assembly
BOB-TACH (POWER) BLOCK
Description
Testing Relief Valve
Removal And Installation
Disassembly And Assembly
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
Description
Removal And Installation
Disassembly And Assembly
AUTOMATIC RIDE CONTROL
Description
Removal And Installation
Checking The Pressure In The Accumulator
Adding Nitrogen To The Accumulator
Parts Identification
Disassembly And Assembly
HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting
HYDROSTATIC DRIVE MOTOR (ONE SPEED)
Description
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
Description
Removal And Installation
Parts Identification
Disassembly
Assembly
HYDROSTATIC MOTOR CARRIER
Description
Removal And Installation
Disassembly
CHARGE PRESSURE
Description
Testing
Sender Removal And Installation
Adjusting (SJC)
HYDROSTATIC PUMP (MANUAL)
Description
Port Locations And Gauge Installation
Removal And Installation
Hydrostatic Pump Startup
Drive Coupler Hub Disassembly And Assembly
Parts Identification
Disassembly And Assembly
HYDROSTATIC PUMP (SJC)
Description
Port Locations And Gauge Installation
Removal And Installation
Hydrostatic Pump Startup
Drive Coupler Hub Disassembly And Assembly
Parts Identification (SJC Pump)
High Pressure Relief And Bypass Valve
Charge Pressure Relief Valve
Disassembly And Assembly
Disassembly And Assembly
Mechanical Neutral Adjustment
Hydraulic Controller Neutral Adjustment
TWO-SPEED VALVE
Description
Valve Block Removal And Installation
Valve Block Disassembly And Assembly
DRAIN MANIFOLD
Description
Drain Manifold Housing Removal And Installation
DRIVE SYSTEM
BRAKE
Description
Block Removal And Installation
DRIVE COMPONENTS
Description
Axle Seal Removal And Installation
Axle, Sprocket And Bearings Removal And Installation
Chain Removal And Installation
CHAINCASE
Description
Chaincase Cover Removal And Installation
MAINFRAME
SEAT BAR
Description
Removal And Installation
Disassembly And Assembly
Compression Spring Disassembly And Assembly
OPERATOR CAB
Gas Spring Removal And Installation
Gas Spring Bracket Disassembly And Assembly
Removal And Installation
OPERATOR SEAT
Removal And Installation
Seat Belt Removal And Installation (Two Point)
Seat Belt Removal And Installation (Three Point)
OPERATOR SEAT (SUSPENSION)
Removal And Installation
Slide Rail Removal And Installation
Seat Belt Removal And Installation
Lower Cushion Removal
Lower Cushion Installation
Back Cushion Removal And Installation
Shock Removal And Installation
3-Point Seat Belt Removal And Installation
BOB-TACH (HAND LEVER)
Description
Removal And Installation
Lever And Wedge Disassembly And Assembly
Pivot Pin Bushing And Seal Removal And Installation
BOB-TACH (POWER)
Description
Removal And Installation
Lever And Wedge Disassembly And Assembly
Pivot Pin Bushing And Seal Removal And Installation
LIFT ARMS
Driver Link Removal And Installation
Follower Link Removal And Installation
Lift Arm Removal And Installation
REAR GRILLE
Raising Rear Grille
Lowering Rear Grille
Shield Removal And Installation
REAR DOOR (TAILGATE)
Removal And Installation
Striker Removal And Installation
Striker Disassembly And Assembly
Striker (Adjusting)
Latch Removal And Installation
FUEL TANK
Removal And Installation
Fuel Level Sender Removal And Installation
Fuel Module Assembly Removal And Installation
Fuel Tank Vent Removal And Installation
Fuel Tank Flushing Plug
CONTROL PEDALS (MANUAL)
Description
Pedal Removal And Installation (Right Side)
Pedal Removal And Installation (Left Side)
Pedal (Adjusting)
FOOTREST (SJC)
Footrest Removal And Installation (Right Side)
Footrest Removal And Installation (Left Side)
CONTROL LEVER ASSEMBLY
Description
Linkage Removal And Installation
Removal And Installation
Disassembly And Assembly
CONTROL LEVER CENTERING ASSEMBLY
Description
Removal And Installation
Disassembly And Assembly
Linkage Neutral (Adjusting)
Linkage Travel (Adjusting)
Shock Removal And Installation
CONTROL HANDLE / LEVER (MANUAL)
Description
Lever Removal And Installation
CONTROL HANDLE / LEVER (SJC)
Description
Joystick Testing
Joystick Removal And Installation
ACCESS PANELS (LOWER)
Removal And Installation (Left Side)
Removal And Installation (Right Side)
ACCESS PANELS (UPPER)
Removal And Installation (Center Panel)
Removal And Installation (Left Side)
Removal And Installation (Right Side)
WINDOW (REAR)
Removing Rear Window With Latches
Removing Rear Window With Rubber Cord
Removing Rear Window With Latches From Outside Loader
Disassembly And Assembly (Latches)
Removal (Rubber Cord)
Installation (Rubber Cord)
WINDOW (TOP)
Removal And Installation
WINDOW (SIDE)
Removal And Installation
CAB DOOR
Description
Removal And Installation
Disassembly And Assembly
Aligning
Adjusting
Checking Operation
ARMREST
Description
Removal And Installation
Disassembly And Assembly
HEADLINER
Removal And Installation
ELECTRICAL SYSTEM
ELECTRICAL SCHEMATICS
STANDARD MACHINE
S/N B4CD11001 & Above
ELECTRICAL SYSTEM
Glossary Of Electrical Symbols
Standard Cab Harness Connectors
Deluxe Cab Harness Connectors
Mainframe Harness Connectors
Electrical System Description
Fuse And Relay Identification
Solenoid Testing
BATTERY
Removing And Installing Battery
Battery Maintenance
Maintaining Battery Charge Level
Battery Service During Machine Storage
Testing Battery
Charging Battery
Using A Booster Battery (Jump Starting)
ALTERNATOR
Adjusting Belt (Machines Without Air Conditioning)
Replacing Belt (Machines Without Air Conditioning)
Adjusting Belt (Machines With Air Conditioning)
Replacing Belt (Machines With Air Conditioning)
Charging System Inspection
Alternator Voltage Testing
Low Voltage Testing
High Voltage Testing
Removal And Installation (Machines Without Air Conditioning)
Removal And Installation (Machines With Air Conditioning)
Parts Identification
STARTER
Testing
Removal And Installation
Parts Identification
INSTRUMENT PANEL IDENTIFICATION
Instrument Panel Overview
Standard Display
Touch Display
Left Control Panel
Right Control Panel
Jog Shuttle (Standard Display)
Jog Shuttle (Touch Display)
Heating, Ventilation, And Air Conditioning (HVAC) Controls
Touch Display Radio Input Ports
Keyed Ignition Kit
Radio Identification
Left Switch Panel Removal And Installation
Right Switch Panel Removal And Installation
LIGHTS
Front Removal And Installation
Rear Removal And Installation
Cab Light Removal And Installation
Side Light Removal And Installation
BOBCAT HUB CONTROLLER
Description
Connector Identification
Removal And Installation
BOBCAT MID CONTROLLER
Description
Removal And Installation
BOBCAT CONTROLLER (SJC) (DRIVE)
Description
Removal And Installation
ENGINE CONTROL UNIT (ECU)
Description
Cleaning
Removal And Installation
DIAGNOSTIC SERVICE CODES
Service Codes List
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
Inspecting The Bobcat Interlock Control System (BICS™)
Inspecting The Lift Arm Bypass Control
SEAT BAR SENSOR
Description
Troubleshooting
Testing
Removal And Installation
Bobcat Interlock Control System (BICS™) Circuit Test
TRACTION LOCK
Description
Troubleshooting
Operating Parking Brake
Operating Hydraulic Controls With Parking Brake Engaged
CONTROL IDENTIFICATION
Identification Chart (Standard)
Identification Chart (SJC)
SERVICE PC (LAPTOP COMPUTER)
Connecting Remote Start Tool (Service Tool)
CALIBRATION
Description
Actuator Testing
Lift And Tilt Calibration (SJC)
Adjusting Lift And Tilt Compensation
Hydrostatic Pump Calibration (SJC)
STEERING DRIFT COMPENSATION
Steering Drift Compensation Description
Adjusting Steering Drift Compensation
NAVIGATION (STANDARD DISPLAY)
Navigation Bar
Viewing Active Shortcuts
VITALS (STANDARD DISPLAY)
Vital Detail And Machine Performance
SERVICE (STANDARD DISPLAY)
Record A Service
SETTINGS (STANDARD DISPLAY)
Display Settings
Machine Settings
Language Settings
Units
Software
GAUGES (TOUCH DISPLAY)
Vital Detail And Machine Performance
Notification Drawer
CAMERA (TOUCH DISPLAY)
Camera Settings
PHONE (TOUCH DISPLAY)
AUDIO (TOUCH DISPLAY)
SERVICE (TOUCH DISPLAY)
Record A Service
View Service Schedule
View Service Record
View Service Codes
ATTACHMENTS (TOUCH DISPLAY)
Attachment Information
SETTINGS (TOUCH DISPLAY)
Favorites
Display Settings
Machine Settings
Security Settings
Security Settings (Manage Operators)
Operator Statistics
Job Clocks
Language Settings
Units
Camera Settings
Bluetooth® Settings
Audio Settings
Dealer
Software
PASSWORD SETUP
Security Settings
Security Settings (Manage Operators)
MAINTENANCE CLOCK
Record A Service
View Service Codes
BACK-UP ALARM SYSTEM
Inspecting Back-Up Alarm System
Adjusting Back-Up Alarm Switches
Troubleshooting (Joystick)
Alarm Removal And Installation
FRONT HORN
Removal And Installation
Troubleshooting
ENGINE SPEED CONTROL (HAND)
Description
Removal And Installation
ENGINE SPEED CONTROL (FOOT)
Description
Removal And Installation
Disassembly And Assembly
CAMSHAFT AND CRANKSHAFT POSITION SENSOR
Removal And Installation
MACHINE IQ
Description
Removal And Installation
LTE/4G Troubleshooting
ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Sensor Location
Torque Values
Troubleshooting
Engine Removal And Installation
Engine Mount Replacement
Compression – Testing
Injector Signal – Testing
Oil Pressure Testing (At Turbocharger Oil Inlet)
DIESEL PARTICULATE FILTER (DPF) SYSTEM
Description
DPF Regeneration Status Icons
DPF Regeneration Tables
Removal And Installation
Automatic Regeneration Operation
Forced Regeneration Operation
Forced Parked Regeneration Operation
Inhibit Mode Operation
AIR CLEANER
Housing Removal And Installation
ENGINE COOLING SYSTEM
Radiator Cooling Package Removal And Installation
Hydraulic Fan Description
Reversible Hydraulic Fan Description
Hydraulic Fan Motor Assembly Removal And Installation
Hydraulic Fan Motor Removal And Installation
Hydraulic Fan Motor Disassembly And Assembly
Water Pump Removal And Installation
Thermostat Housing Removal And Installation
Testing The Thermostat
LUBRICATION SYSTEM
Description
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Relief Valve Description
Oil Pump Relief Valve Removal And Installation
Oil Cooler Removal And Installation
Oil Filter Head Removal And Installation
Oil Cooler Bypass Description
Oil Cooler Bypass Removal And Installation
FUEL SYSTEM
Description
Fuel Filter Housing Removal And Installation
Fuel Lift Pump Removal And Installation
Fuel Lift Pump Filter Removal And Installation
Transfer Pump / High Pressure Pump Removal And Installation
Fuel Temperature Sensor Removal And Installation
Fuel Recirculation Valve (FRV) Removal And Installation
Fuel Pressure Relief Valve Removal And Installation
Fuel Rail Assembly Removal And Installation
Fuel Injector Removal And Installation
Injector Coding
CYLINDER HEAD
Glow Plugs Testing
Glow Plug Removal And Installation
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head Inspection
Cylinder Head Top Clearance
Valve Step Height
Valve Stem Height
Valve Guide
Valve
Valve Spring
Rocker Arm Shaft Disassembly And Assembly
Rocker Arm Shaft Inspection
Installing The Rocker Arm Assembly
Push Rod Inspection
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod Inspection
Crankshaft Removal And Installation
Cylinder Block Inspection
Crankshaft Inspection
Connecting Rod Inspection
Engine Component Class
CAMSHAFT
Removal And Installation
Inspecting
GEARCASE
Gearcase Cover Removal And Installation
Gear Backlash
Gear Timing
Idle Gear Removal And Installation
Idle Gear Inspection
TURBOCHARGER
Description
Removal And Installation
Inspection
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Housing Removal And Installation
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Description
Removal And Installation
EXHAUST MANIFOLD
Removal And Installation
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW
Description (Standard HVAC)
Description (Auto HVAC)
Standard HVAC Chart
Auto HVAC Chart
Components
Safety Equipment
REGULAR MAINTENANCE
Cleaning HVAC Filters
Cleaning Air Conditioning Evaporator And Heater Coil
Cleaning Air Conditioning Condenser
Lubricating Air Conditioning System
Troubleshooting HVAC System
Adjusting Belt
Replacing Belt
Air Conditioning Service Chart
TROUBLESHOOTING
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
The Compressor Does Not Operate At All, Or Operates Improperly
Gauge Pressure Related Troubleshooting
Troubleshooting Tree
Temperature / Pressure Chart
Poor A/C Performance
HVAC Repair And Leaks
Electrical System
Engine Coolant Bypassing The Heater Valve
Heater Valve Not Opening Or Closing
SYSTEM CHARGING AND RECLAMATION
Refrigerant Identification
Reclamation And Charging With Recovery / Charging Unit
COMPRESSOR
Removal And Installation
Oil
Oil Check
CONDENSER
Removal And Installation
RECEIVER / DRIER FILTER CARTRIDGE
Removal And Installation
HVAC ASSEMBLY
Removal And Installation
THERMOSTAT
Description
Removal And Installation
EXPANSION VALVE
Removal And Installation
EVAPORATOR COIL
Removal And Installation
HEATER COIL
Removal And Installation
BLOWER FAN
Removal And Installation
Disassembly And Assembly
HEATER VALVE
Removal And Installation (Standard HVAC)
Removal And Installation (Auto HVAC)
EVAPORATOR / HEATER COVER
Removing
Installing
AUTO HVAC MODULE
Removal And Installation
SPECIFICATIONS
LOADER SPECIFICATIONS
Machine Dimensions
Performance Specifications
Engine Specifications
Drive System Specifications
Control Specifications
Hydraulic System Specifications
Hydraulic Cylinder Specifications
Electrical System Specifications
Fluid Capacities
Tyre Specifications
Engine CO2 Emission Values
TECHINCAL SERVICE GUIDE SPECIFICATIONS
Engine
Engine Torques
Cooling System
Loader Torques
Hydraulic / Hydrostatic System
Fuel Consumption
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
Straight Thread O-ring Fitting
Flare Fitting
Tubelines And Hoses
HYDRAULIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalent Chart
U.S. To Metric Conversion Chart
SERVICE TOOLS REQUIRED
Remote Start Tools
Hydraulic Tools
Mainframe And Drive Tools
Electrical Tools
Engine Tools
HVAC Tools
ALPHABETICAL INDEX
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