Bobcat A300 Turbo A300 Turbo High Flow Loader Service Manual 6901932 (6-12) – PDF DOWNLOAD

Description

Bobcat A300 Turbo A300 Turbo High Flow Loader Service Manual 6901932 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat A300 Turbo A300 Turbo High Flow Loader Service Manual 6901932 (6-12) – PDF DOWNLOAD

Language : English
Pages : 748
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat A300 Turbo A300 Turbo High Flow Loader Service Manual 6901932 (6-12) – PDF DOWNLOAD

S/N 523411001 & Above
S/N 523511001 & Above

FOREWORD:

This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

SAFETY INSTRUCTIONS:

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:

TABLE OF CONTENTS:

Bobcat A300 Turbo A300 Turbo High Flow Loader Service Manual 6901932 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
Fire Prevention 13
SERIAL NUMBER LOCATION 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
BOBCAT LOADER IDENTIFICATION 17
SAFETY AND MAINTENANCE 19
LIFTING AND BLOCKING THE LOADER 21
Procedure 21
LIFT ARM SUPPORT DEVICE 23
Installing The Lift Arm Support Device 23
Removing The Lift Arm Support Device 24
OPERATOR CAB 25
Description 25
Raising The Operator Cab 25
Lowering The Operator Cab 26
Emergency Exit 26
TRANSPORTING THE BOBCAT LOADER 29
Procedure 29
TOWING THE LOADER 31
Procedure 31
REMOTE START 33
Procedure For Loader W/O Attachments Control Harness 33
Procedure For Loader With Attachments Control Harness 34
Procedure 35
SERVICE SCHEDULE 37
Chart 37
AIR CLEANER SERVICE 39
Replacing Filter Element 39
ENGINE COOLING SYSTEM 41
Cleaning Cooling System 41
FUEL SYSTEM 43
Fuel Specifications 43
Filling The Fuel Tank 43
Fuel Filter 44
Removing Air From The Fuel System 44
ENGINE LUBRICATION SYSTEM 45
Checking Engine Oil 45
Oil Chart 45
Replacing Oil And Filter 45
HYDRAULIC/HYDROSTATIC SYSTEM 47
Checking And Adding Fluid 47
Hydraulic/Hydrostatic Filter Replacement 47
Replacing Hydraulic Fluid And Case Drain Filters 48
Steering Filter Replacement 49
FINAL DRIVE TRANSMISSION (CHAINCASE) 51
Checking And Adding Oil 51
Replacing The Oil 51
FAN GEARBOX 53
Checking And Adding Oil 53
BOB-TACH 55
Inspection And Maintenance 55
POWER BOB-TACH 57
Inspection And Maintenance 57
LUBRICATING THE LOADER 59
Procedure 59
TIRE MAINTENANCE 63
Wheel Nuts 63
Tire Rotation 63
Tire Mounting 63
HYDRAULIC SYSTEM 65
HYDRAULIC/HYDROSTATIC SCHEMATICS 69
HYDRAULIC SYSTEM INFORMATION 73
Tighten Procedures 78
CYLINDER (LIFT) 79
Checking 79
Removal And Installation 79
Parts Identification 81
Disassembly 82
Assembly 83
CYLINDER (TILT) 87
Checking 87
Removal And Installation 87
Base Pin Removal And Installation 89
Parts Identification 90
Disassembly 91
Assembly 92
CYLINDER (POWER BOB-TACH) 95
Checking 95
Removal And Installation 96
Parts Identification 97
Disassembly 98
Assembly 99
CYLINDER (STEERING) 103
Removal (Front) 103
Removal (Rear) 106
MAIN RELIEF VALVE 109
Checking The Main Relief Valve At Front Auxiliary Hydraulics 109
Removal and Installation 110
Adjustment 111
HYDRAULIC CONTROL VALVE 113
Actuator Removal And Installation (In Loader) 113
Removal And Installation 115
Actuator Removal And Installation (Out Of Loader) 119
BICS™ Valve Removal And Installation 120
BICS™ Valve Lift Arm By-Pass Orifice Removal And Installation 121
BICS™ Valve Check Valve Removal And Installation 121
BICS™ Valve Lock Valve Removal And Installation 122
BICS™ Valve Soleniod Removal And Installation 123
BICS™ Valve Solenoid Testing 124
Identification Chart 125
Lift Base End Restrictor 126
Load Check Valve 126
Main Relief Valve 127
Port Relief Valve 128
Anti-Cavitation Valve/Port Relief Valve 129
Anti-Cavitation Valve 130
Lift Spool Removal And Installation 130
Tilt Spool Removal And Installation 131
Lift And Tilt Spool Disassembly And Assembly 132
Auxiliary Spool Removal And Installation 133
Auxiliary Electric Solenoid Disassembly And Assembly 134
Port-Auxiliary Section Disassembly 135
Cleaning And Inspection 136
LIFT ARM BY-PASS CONTROL VALVE 137
Inspecting 137
Additional Inspection For Loaders W/Advanced Hand Controls 137
Removal And Installation 137
Disassembly And Assembly 138
HYDRAULIC PUMP 139
Checking The Output Of The Auxiliary Pump 139
Checking The Output Of The Steering Pump 140
Removal And Installation 141
Parts Identification 144
Disassembly And Assembly 145
HYDRAULIC PUMP (HI FLOW) 153
Checking The Output Of The High Flow Pump 153
Removal And Installation 155
Parts Identification 159
Disassembly And Assembly 160
HYDRAULIC/HYDROSTATIC FILTER 173
Housing Removal And Installation 173
Mount Removal And Installation 174
HYDRAULIC FLUID RESERVOIR 175
Fluid Removal 175
Removal And Installation 175
Hydraulic Fluid Screen 178
BUCKET POSITION VALVE 179
Solenoid Removal And Installation 179
Solenoid Testing 179
Removal And Installation 180
Disassembly And Assembly 180
HIGH FLOW VALVE 183
Checking The High Flow Relief Valve 183
High Flow Relief Valve Adjustment Procedure 185
Removal and Installation 186
Disassembly And Assembly 188
Solenoid Testing 190
REAR AUXILIARY DIVERTER 191
Removal and Installation 191
REAR AUXILIARY DIVERTER (CONT’D) 192
Disassembly And Assembly 193
Solenoid Testing 198
Inspection 198
POWER BOB-TACH BLOCK (EARLY MODELS) 199
Removal And Installation 199
Disassembly And Assembly 202
POWER BOB-TACH BLOCK (LATER MODELS) 211
Removal And Installation 211
Disassembly And Assembly 214
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 219
Removal and Installation 219
Disassembly And Assembly 219
HYDROSTATIC SYSTEM 221
HYDROSTATIC SYSTEM INFORMATION 223
Troubleshooting Chart 223
Replenishing Valve Function 224
HYDROSTATIC MOTOR 225
Removal And Installation 225
Parts Identification 227
Disassembly 229
Inspection 235
Assembly 237
HYDROSTATIC MOTOR CARRIER 243
Removal And Installation 243
Parts Identification 244
Disassembly 245
Assembly 247
CHARGE PRESSURE SENDER 253
Testing 253
Removal And Installation 254
HYDROSTATIC PUMP 255
Pump Controller Removal And Installation 255
Hydrostatic Pump Calibration 258
Removal And Installation 262
Parts Identification (Right Half) 265
Parts Identification (Left Half) 267
System Check Relief Valves (High Pressure Relief, Charge Check & By-Pass Valve) 269
Charge Relief Valve 270
Pump Separation 272
Shaft Seal And Shaft Replacement 273
Shaft Seal And Shaft Installation 275
Charge Pump Removal 277
Charge Pump Inspection 279
Charge Pump Installation 280
Disassembly 282
Inspection 289
Assembly 293
Pump Neutral Adjustment 302
Pump Controller Neutral Adjustment 305
DRIVE BELT 311
Shield Removal And Installation 311
Adjustment 311
Replacement 311
Tensioner Pulley Removal And Installation 312
Tensioner Pulley Tension Spring 314
OIL COOLER (SEAL TO CONNECT) (STC) 315
Hydraulic Oil Cooler Removal and Installation 315
DRIVE SYSTEM 317
BRAKE 319
Block Removal And Installation 319
Block Disassembly And Assembly 320
STEERING BLOCK 326
Wiring Diagram 326
Removal And Installation 328
Disassembly And Assembly 329
DRIVE COMPONENTS 337
Axle Seal Removal And Installation 337
Axle, Sprocket And Bearings Removal And Installation 338
Drive Chain Removal And Installation 343
CHAINCASE 345
Front Chaincase Cover Removal And Installation 345
Rear Chaincase Cover Removal And Installation 345
HUB 347
Removal 347
Installation 349
Disassembly 353
Inspection 356
Assembly 357
MAIN FRAME 361
SEAT BAR 363
Removal And Installation 363
Assembling Components 364
Compression Spring Disassembly And Assembly 365
OPERATOR CAB 367
Gas Cylinder Removal And Installation (Early Models) 367
Gas Cylinder Removal And Installation (Later Models) 369
Gas Cylinder Bracket Disassembly And Assembly 371
Removal And Installation 371
OPERATOR SEAT 375
Removal And Installation 375
Seat Belt Removal And Installation 375
OPERATOR SEAT (SUSPENSION) 377
Removal And Installation 377
Slide Rail Removal And Installation 378
Cushion Removal And Installation 378
Back Removal And Installation 379
Shock Removal And Installation 380
BOB-TACH 381
Removal And Installation 381
Bob-Tach Lever And Wedge 383
POWER BOB-TACH 385
Removal And Installation 385
Power Bob-Tach Lever And Wedge 387
Pivot Pin Bushing And Seal Replacement 389
LIFT ARMS 391
Stabilizer Bar Removal And Installation 391
Link Removal And Installation 392
Removal And Installation 393
Installation Of Lift Arms 395
REAR GRILL 397
Removal And Installation 397
REAR DOOR 399
Removal And Installation 399
Adjusting The Rear Door Latch 400
FUEL TANK 401
Removal And Installation 401
Fuel Level Sender 402
CONTROL 403
Joystick Testing (Right & Left) 403
Joystick Removal (Right & Left) 404
Joystick Boot Removal (Right & Left) 405
Lever Assembly Removal (Right & Left) 405
CONTROL PANEL 407
Removal And Installation 407
INSIDE ACCESS PANEL 411
Panel Removal (Right) 411
Panel Removal (Left) 414
ELECTRICAL SYSTEM & ANALYSIS 415
ELECTRICAL SCHEMATICS 419
ELECTRICAL SYSTEM INFORMATION 423
Troubleshooting 425
Description 426
Fuse Location 427
Relay Switch Location 427
Solenoid Test 427
BATTERY 429
Removal And Installation 429
Servicing The Electrical System 431
Using A Booster Battery (Jump Starting) 432
ALTERNATOR 433
Adjusting The Alternator Belt 433
Alternator Identification 433
Charging System Check 434
Alternator Voltage Test 435
Low Voltage Test 435
High Voltage Test 436
Removal And Installation 436
Rectifier Continuity (Diode) Test 437
Alternator Regulator Test 438
Disassembly 439
Stator Continuity Test 439
Stator Ground Test 439
Rotor Continuity Test 440
Rotor Ground Test 440
Assembly 440
STARTER 441
Removal And Installation 441
Parts Identification 442
Checking 443
Disassembly And Assembly 444
Inspection And Repair 447
No Load Test 450
INSTRUMENT PANEL 451
Left Panel 451
Right Panel – (Standard) (With Key Switch) 452
Right Panel – (Deluxe) (With Keyless Start) 453
Right Panel Set Up Display Options (Deluxe) 454
Option and Field Accessory Panels (If Equipped) 458
Standard Panel Removal And Installation (Right Side) 460
Deluxe Panel Removal And Installation (Right Side) 461
Standard & Deluxe Panel Removal And Installation (Left Side) 462
LIGHTS 465
Front Removal And Installation 465
Rear Removal And Installation 466
BOBCAT CONTROLLER 468
Identification Chart 468
Removal And Installation 470
AWS CONTROLLER 473
Removal 473
Identification Chart 476
SPEED SENSOR 479
Testing 479
Removal 480
DIAGNOSTICS SERVICE CODES 483
Display 483
Number Codes List 485
STEERING SOLENOID 489
Removal 489
BICS™ SYSTEM 491
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 491
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 491
Inspecting The Seat Bar Sensor (Engine RUNNING) 491
Inspecting The Traction Lock (Engine RUNNING) 491
Troubleshooting Chart 492
Troubleshooting Guide 493
SEAT BAR SENSOR 495
Troubleshooting Chart 495
Test 496
Removal And Installation 497
BICS™ Circuit Test 498
TRACTION LOCK 499
Troubleshooting Chart 499
Description Of The Control System 500
Inspecting The Control System 500
WHEEL POSITION SENSORS 501
Operation 501
Wheel Alignment (Failed Sensor) 502
Testing 503
Sensor Removal And Installation 504
Wheel Alignment (Field Adjustment) 506
Wheel Alignment (Calibration) 510
SERVICE PC (LAPTOP COMPUTER) 515
Connecting The Service PC To Remote Start Tool 515
LIFT AND TILT ACTUATOR CALIBRATION 517
Procedure 517
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE 520
Controls Identification Chart 520
FLYWHEEL RPM SENSOR 523
Adjustment 523
ENGINE SERVICE 525
TROUBLESHOOTING 529
Chart 529
ENGINE SPEED CONTROL 531
Removal 531
Disassembly 533
Speed Control Cable 534
MUFFLER 535
Removal And Installation 535
AIR CLEANER 537
Housing Removal And Installation 537
RADIATOR 539
Removal And Installation 539
Mount Removal 541
COOLING FAN 543
Drive Tension Pulley Removal And Installation 543
Gearbox/Blower Housing Removal And Installation 544
Blower Removal And Installation 547
Gearbox Parts Identification 548
Gearbox Disassembly 549
Gearbox Assembly 554
Gearbox, Checking Backlash 559
ENGINE 563
Removal And Installation 563
Mount Replacement 570
Removal And Installation Tools 571
FLYWHEEL AND HOUSING 573
Flywheel Removal And Installation 573
Ring Gear Removal And Installation 573
Flywheel Housing Removal And Installation 573
RECONDITIONING THE ENGINE 575
Engine Tools Identification Chart 575
Compression Pressure 579
Cylinder Head Clearance 579
Valve Cover And Injector Nozzle Removal And Installation 580
Rocker Arm And Push Rod Disassembly And Assembly 582
Valve Clearance 582
Cylinder Head And Tappet Disassembly And Assembly 583
Selecting Cylinder Head Gasket Disassembly And Assembly 584
Valve Disassembly And Assembly 585
Engine Timing (TDC) 586
Injection Pump Assembly Removal 587
Injection Pump Assembly Installation 590
Injection Pump Removal and Installation 593
Injection Pump Timing 595
Fan Drive Pulley Disassembly And Assembly 598
Water Pump Disassembly And Assembly 598
Gearcase Cover Disassembly And Assembly 599
Idle Gear And Camshaft Disassembly And Assembly 599
Gearcase Plate Disassembly And Assembly 600
Oil Pan And Oil Strainer Disassembly And Assembly 600
Connecting Rod Cap Disassembly And Assembly 601
Piston Disassembly And Assembly 602
Piston Ring And Connecting Rod Disassembly And Assembly 603
Bearing Case Cover Disassembly And Assembly 605
Flywheel Housing Disassembly And Assembly 606
Crankcase No 2 Disassembly And Assembly 606
Crankcase No 1 And No 2 Disassembly And Assembly 607
Crankshaft Disassembly And Assembly 607
Cylinder Head Surface Flatness 607
Cylinder Head Flaw 608
Valve Recessing 608
Valve Lapping 609
Clearance Between Valve Stem And Valve Guide 609
Replacing Valve Guide 610
Correcting Valve And Valve Seat 610
Free Length And Tilt Of Valve Spring 611
Valve Spring Setting Load 611
Oil Clearance Between Rocker Arm Shaft And Bearing 612
Oil Clearance Between Tappet And Tappet Guide Bore 612
Timing Gear Backlash 613
Idler Gear Side Clearance 613
Camshaft Side Clearance 614
Camshaft Alignment 614
Cam Height 614
Oil Clearance Between Idler Gear Shaft And Idler Gearing Bushing 615
Replacing Idler Gear Bushing 616
Piston Pin Bore I D 617
Oil Clearance Between Piston Pin And Small End Bushing 617
Replacing Small End Bushing 618
Clearance Between Piston Ring And Groove 618
Piston Ring Gap 619
Connecting Rod Alignment 619
Crankshaft Side Clearance 620
Crankshaft Alignment 621
Oil Clearance Between Crankpin And Crankpin Bearing 621
Oil Clearance Between Crankshaft Journal And Crankshaft Bearing 623
Replacing Crankshaft Sleeve 624
Cylinder Bore I D 624
Correcting Cylinder (Oversize +0 5 mm) 625
Engine Oil Pressure 625
Rotor Lobe Clearance 626
Clearance Between Outer Rotor And Pump Body 626
Thermostat Valve Opening Temperature 626
Radiator Water Leakage 627
Radiator Cap Air Leakage 627
Thermostat Assembly 627
Intake Air Heater 628
Checking the Turbo Charger 629
Compressor Side 629
Wheel Shaft 629
Axial Clearance 630
Radial Clearance 630
Air Cleaner, Intake Pipe, Inlet Pipe And Muffler 630
Oil Pipe 631
HEATING, VENTILATION, AIR CONDITIONING 633
AIR CONDITIONING SYSTEM FLOW 636
Principals 636
Chart 637
COMPONENTS 639
Identification 639
SAFETY 643
Safety Equipment 643
REGULAR MAINTENANCE 645
Filter Elements Removal And Installation 645
Compressor Drive Belt Inspection 646
Cleaning The Condenser 647
BASIC TROUBLESHOOTING 649
Poor A/C Performance 649
Cleaning The A/C Evaporator Coil & Heater Coil 650
Compressor Drive Belt Inspection 650
Checking The Electrical System 651
Engine Coolant By-Passing The Heater Valve 659
Heater Valve Not Opening Or Closing 660
GENERAL AIR CONDITIONING SERVICE GUIDELINES 661
Compressor Oil 661
Compressor Oil Check 662
Component Replacement And Refrigeration Leaks 663
SYSTEM TROUBLESHOOTING CHART 665
Gauge Pressure Related Troubleshooting 666
Troubleshooting Tree 668
TEMPERATURE/PRESSURE 673
Chart 673
AIR CONDITIONING SERVICE 675
Chart 675
SYSTEM CHARGING AND RECLAMATION 677
Reclamation Procedure 677
Charging Procedure With A Manifold Gauge Set 679
Charging Procedure 680
COMPRESSOR 683
Removal And Installation 683
Compressor Clutch Disassembly 684
CONDENSER 689
Removal And Installation 689
RECEIVER/DRIER 691
Removal And Installation 691
PRESSURE RELIEF VALVE 693
Removal And Installation 693
PRESSURE SWITCH 695
Removal And Installation 695
EVAPORATOR/HEATER UNIT 697
Removal And Installation 697
Disassembly And Assembly 698
THERMOSTAT 699
Removal And Installation 699
EXPANSION VALVE 701
Removal And Installation 701
EVAPORATOR 703
Removal And Installation 703
HEATER COIL 705
Removal And Installation With A/C 705
Removal And Installation Without A/C 706
BLOWER FAN 707
Removal And Installation 707
Disassembly And Assembly 708
Wire Connector Removal and Installation 710
HEATER VALVE 713
Removal and Installation 713
Disassembly And Assembly 714
SPECIFICATIONS 717
LOADER SPECIFICATIONS (A300) 719
Machine Dimensions 719
Performance 720
Controls 720
Engine 720
Hydraulic System 721
Electrical 721
Drive System 722
Capacities 722
Tires 722
ENGINE SPECIFICATIONS 723
General 723
Fuel System 723
Valve And Valve Timing 723
Valve Spring 724
Piston And Piston Ring 724
Connecting Rod 724
Cylinder Head 725
Crankshaft 725
Cylinder Bore 725
Oil Pump 725
Rocker Arm 726
Tappet 726
Camshaft 726
Thermostat 726
Timing Gear 727
Intake Air Heater 727
TORQUE SPECIFICATIONS FOR BOLTS 729
Torque For General SAE Bolts 729
Torque For General Metric Bolts 730
Torque For Kubota Metric Engine Bolts 731
Tightening Torques For General Use Screws, Bolts And Nuts 731
HYDRAULIC CONNECTION SPECIFICATIONS 733
O-ring Face Seal Connection 733
Straight Thread O-ring Fitting 734
Tubelines And Hoses 734
Flare Fitting 734
O-ring Flare Fitting 735
Port Seal Fitting 737
HYDRAULIC FLUID SPECIFICATIONS 739
Specifications 739
CONVERSIONS 741
Decimal And Millimeter Equivalents 741
SMR 743
Revision No: A300-1 743
Revision No : A300-2 745
Revision No: A300-3 747

IMAGES PREVIEW OF THE MANUAL:

Customer Support: [email protected]

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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