Bobcat A300 Turbo A300 Turbo High Flow Loader Service Manual 6902728 (6-12) – PDF DOWNLOAD

Description

Bobcat A300 Turbo A300 Turbo High Flow Loader Service Manual 6902728 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat A300 Turbo A300 Turbo High Flow Loader Service Manual 6902728 (6-12) – PDF DOWNLOAD

Language : English
Pages : 804
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat A300 Turbo A300 Turbo High Flow Loader Service Manual 6902728 (6-12) – PDF DOWNLOAD

S/N 526411001 & Above
S/N 526511001 & 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 6902728 (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
Checking The Coolant Level 43
Adding The Coolant 44
FUEL SYSTEM 45
Fuel Specifications 45
Filling The Fuel Tank 45
Fuel Filter 46
Removing Air From The Fuel System 46
ENGINE LUBRICATION SYSTEM 47
Checking Engine Oil 47
Oil Chart 47
Replacing Oil And Filter 47
HYDRAULIC/HYDROSTATIC SYSTEM 49
Checking And Adding Fluid 49
Hydraulic Fluid Chart 49
Hydraulic/Hydrostatic Filter Replacement 50
Replacing Hydraulic Fluid And Case Drain Filters 51
FINAL DRIVE TRANSMISSION (CHAINCASE) 53
Checking And Adding Oil 53
Removing The Oil 53
FAN GEARBOX 55
Checking And Adding Oil 55
BOB-TACH 57
Inspection And Maintenance 57
POWER BOB-TACH 59
Inspection And Maintenance 59
LUBRICATING THE LOADER 61
Procedure 61
TIRE MAINTENANCE 65
Wheel Nuts 65
Tire Rotation 65
Tire Mounting 65
HYDRAULIC SYSTEM 67
HYDRAULIC/HYDROSTATIC SCHEMATICS 71
HYDRAULIC SYSTEM INFORMATION 79
Troubleshooting 83
Tighten Procedures 84
CYLINDER (LIFT) 85
Checking 85
Removal And Installation 85
Parts Identification 87
Disassembly 88
Assembly 89
CYLINDER (TILT) 93
Checking 93
Removal And Installation 93
Base Pin Removal And Installation 95
Parts Identification 96
Disassembly 97
Assembly 98
CYLINDER (POWER BOB-TACH) 101
Checking 101
Removal And Installation 102
Parts Identification 103
Disassembly 104
Assembly 105
CYLINDER (STEERING) 109
Removal (Front) 109
Removal (Rear) 112
MAIN RELIEF VALVE 115
Checking Main Relief 115
Adjustment 117
Removal And Installation 118
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) 119
Identification 119
Removal And Installation 120
Actuator Removal And Installation (In Loader) 124
Actuator Removal And Installation (Out Of Loader) 127
BICS™ Valve Removal And Installation 129
BICS™ Valve Lift Arm By-Pass Orifice Removal And Installation 130
BICS™ Valve Check Valve Removal And Installation 131
BICS™ Valve Lock Valve Removal And Installation 132
BICS™ Valve Solenoid Removal And Installation 133
BICS™ Valve Solenoid Testing 134
Identification Chart 135
Lift Base End Restrictor 136
Load Check Valve 136
Main Relief Valve 137
Port Relief Valve 138
Anti-Cavitation Valve/Port Relief Valve 139
Anti-Cavitation Valve 140
Lift Spool Removal And Installation 140
Tilt Spool Removal And Installation 141
Lift And Tilt Spool Disassembly And Assembly 142
Auxiliary Spool Removal And Installation 143
Auxiliary Electric Solenoid Disassembly And Assembly 144
Port-Auxiliary Section Disassembly 146
Cleaning And Inspection 147
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) 149
Identification 149
Removal And Installation 150
Actuator Removal And Installation (In Loader) 154
Identification Chart 159
BICS™ Valve, Lift Load Check Valve Removal And Installation 160
Load Check Valve Removal And Installation (Tilt & Auxiliary) 161
Anti-Cavitation Valve (Lift, Rod End) 161
Port Relief/Anti-Cavitation Valve (Lift, Base End) 162
Port Relief/Anti-Cavitation Valve (Tilt, Base End) 163
Port Relief/Anti-Cavitation Valve (Tilt, Rod End) 163
Port Relief Valve 164
Plug Removal 165
End Cap Block Removal and Installation 166
Lift Spool Removal and Installation 167
Auxiliary Spool Removal And Installation 173
Auxiliary Solenoid Disassembly and Assembly 175
BICS™ Valve Solenoid Disassembly And Assembly 176
BICS™ Valve, Lock Valve Removal And Installation 177
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly 179
Main Relief Valve 179
BICS™ Valve, Check Valve Removal And Installation 180
LIFT ARM BY-PASS CONTROL VALVE 181
Inspecting 181
Additional Inspection For Loaders W/Advanced Hand Controls 181
Removal And Installation 181
Disassembly And Assembly 182
HYDRAULIC PUMP 183
Checking The Output Of The Auxiliary Pump 183
Checking The Output Of The Steering Pump 184
Removal And Installation 185
Parts Identification 188
Disassembly And Assembly 189
HYDRAULIC PUMP (HIgh FLOW) 197
Checking The Output Of The High Flow Pump (30 GPM And 40 GPM) 197
Removal And Installation (30 GPM And 40 GPM) 199
Parts Identification (30 GPM And 40 GPM) 203
Disassembly And Assembly (30 GPM And 40 GPM) 204
HYDRAULIC/HYDROSTATIC FILTER 217
Housing Removal And Installation 217
Mount Removal And Installation 218
HYDRAULIC FLUID RESERVOIR 219
Fluid Removal 219
Removal And Installation 219
Hydraulic Fluid Screen 222
BUCKET POSITION VALVE 223
Solenoid Removal And Installation 223
Solenoid Testing 223
Removal And Installation 224
Disassembly And Assembly 224
HIGH FLOW VALVE 227
Checking The High Flow Relief Valve 227
High Flow Relief Valve Adjustment Procedure 229
Removal and Installation 230
Disassembly And Assembly 232
Solenoid Testing 234
REAR AUXILIARY DIVERTER VALVE 235
Removal And Installation 235
Disassembly And Assembly 237
Solenoid Testing 242
Inspection 242
POWER BOB-TACH BLOCK 243
Removal And Installation 243
Disassembly And Assembly 246
Front Auxiliary hydraulic coupler Block 251
Removal and Installation 251
Disassembly And Assembly 251
HYDROSTATIC SYSTEM 253
HYDROSTATIC SYSTEM INFORMATION 255
Troubleshooting Chart 255
Replenishing Valve Function 256
HYDROSTATIC MOTOR 257
Removal And Installation 257
Parts Identification 259
Disassembly 261
Inspection 267
Assembly 269
HYDROSTATIC MOTOR CARRIER 275
Removal And Installation 275
Parts Identification 276
Disassembly 277
Assembly 279
CHARGE PRESSURE SENDER 283
Testing 283
Removal And Installation 284
HYDROSTATIC PUMP 285
Pump Controller Removal And Installation 285
Hydrostatic Pump Calibration 288
Removal And Installation 293
Parts Identification (Right Half) 295
Parts Identification (Left Half) 297
System Check Relief Valves (High Pressure Relief, Charge Check & By-Pass Valve) 299
Charge Relief Valve 300
Pump Separation 302
Shaft Seal And Shaft Replacement 303
Shaft Seal And Shaft Installation 305
Charge Pump Removal 307
Charge Pump Inspection 309
Charge Pump Installation 310
Disassembly 312
Inspection 319
Assembly 323
Pump Neutral Adjustment 332
Pump Controller Neutral Adjustment 335
DRIVE BELT 339
Shield Removal And Installation 339
Adjustment 339
Replacement 339
Tensioner Pulley Removal And Installation 340
Tensioner Pulley Tension Spring 342
OIL COOLER (SEAL TO CONNECT) (STC) 343
Hydraulic Oil Cooler Removal And Installation 343
DRIVE SYSTEM 345
BRAKE 347
Block Removal And Installation 347
Block Disassembly And Assembly 348
STEERING BLOCK 354
Identification 354
Removal And Installation 356
Disassembly And Assembly 357
DRIVE COMPONENTS 365
Axle Seal Removal And Installation 365
Axle, Sprocket And Bearings Removal And Installation 366
Drive Chain Removal And Installation 371
CHAINCASE 373
Front Chaincase Cover Removal And Installation 373
Rear Chaincase Cover Removal And Installation 373
HUB 375
Removal 375
Installation 377
Disassembly 381
Inspection 384
Assembly 385
MAIN FRAME 389
SEAT BAR 391
Removal And Installation 391
Assembling Components 392
Compression Spring Disassembly And Assembly 393
OPERATOR CAB 395
Gas Cylinder Removal And Installation (Early Models) 395
Gas Cylinder Removal And Installation (Later Models) 397
Gas Cylinder Bracket Disassembly And Assembly 399
Removal And Installation 399
OPERATOR SEAT 403
Removal And Installation 403
Seat Belt Removal And Installation 403
OPERATOR SEAT (SUSPENSION) 405
Removal And Installation 405
Slide Rail Removal And Installation 406
Seat Belt Removal And Installation 406
Cushion Removal And Installation 407
Back Removal And Installation 408
Shock Removal And Installation 408
3-Point Seat Belt Removal And Installation 409
BOB-TACH 411
Removal And Installation 411
Bob-Tach Lever And Wedge 413
POWER BOB-TACH 415
Removal And Installation 415
Power Bob-Tach Lever And Wedge 417
Pivot Pin Bushing And Seal Replacement 419
LIFT ARMS 421
Stabilizer Bar Removal And Installation 421
Link Removal And Installation 422
Removal And Installation 423
Installation Of Lift Arms 425
REAR GRILL 427
Removal And Installation 427
REAR DOOR 429
Removal And Installation 429
Striker Removal and Installation 430
Striker Disassembly and Assembly 430
Door Latch and Catch Adjustment 430
Latch Removal And Installation 431
FUEL TANK 433
Removal And Installation 433
Fuel Level Sender 434
CONTROL 435
Joystick Testing (Right & Left) 435
Joystick Removal (Right & Left) 436
Joystick Boot Removal (Right & Left) 437
Lever Assembly Removal (Right & Left) 437
CONTROL PANEL 439
Removal And Installation 439
INSIDE ACCESS PANEL 443
Panel Removal (Right) 443
Panel Removal (Left) 446
ELECTRICAL SYSTEM & ANALYSIS 447
ELECTRICAL SCHEMATICS 451
ELECTRICAL SYSTEM INFORMATION 455
Troubleshooting 457
Description 458
Fuse Location 459
Relay Switch Location 459
Solenoid Test 459
BATTERY 461
Removal And Installation 461
Servicing The Electrical System 463
Using A Booster Battery (Jump Starting) 464
ALTERNATOR 465
Adjusting The Alternator Belt 465
Alternator Identification 465
Charging System Check 466
Alternator Voltage Test 467
Low Voltage Test 467
High Voltage Test 468
Removal And Installation 468
Rectifier Continuity (Diode) Test 469
Alternator Regulator Test 470
Disassembly 471
Stator Continuity Test 471
Stator Ground Test 471
Rotor Continuity Test 472
Rotor Ground Test 472
Assembly 472
STARTER 473
Checking 473
Removal And Installation 474
Parts Identification 475
Disassembly And Assembly 476
Inspection And Repair 479
No Load Test 482
INSTRUMENT PANEL 483
Left Panel 483
Right Panel – (Standard) (With Key Switch) 484
Right Panel – (Deluxe) (With Keyless Start) 485
Right Panel Set Up Display Options (Deluxe) 486
Option and Field Accessory Panels (If Equipped) 490
Standard Panel Removal And Installation (Right Side) 492
Deluxe Panel Removal And Installation (Right Side) 493
Standard & Deluxe Panel Removal And Installation (Left Side) 494
LIGHTS 497
Front Removal And Installation 497
Rear Removal And Installation 498
BOBCAT CONTROLLER 500
Identification Chart 500
Removal And Installation 502
AWS CONTROLLER 505
Removal 505
Identification Chart 508
SPEED SENSOR 511
Testing 511
Removal 512
DIAGNOSTICS SERVICE CODES 515
Display 515
Number Codes List 516
STEERING SOLENOID 521
Removal 521
BICS™ SYSTEM 523
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 523
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 523
Inspecting The Seat Bar Sensor (Engine RUNNING) 523
Inspecting The Traction Lock (Engine RUNNING) 523
Troubleshooting 524
Troubleshooting Chart 525
SEAT BAR SENSOR 527
Troubleshooting Chart 527
Test 528
Removal And Installation 529
BICS™ Circuit Test 530
TRACTION LOCK 531
Troubleshooting 531
Description Of The Control System 532
Inspecting The Control System 532
WHEEL POSITION SENSORS 533
Operation 533
Wheel Alignment (Failed Sensor) 534
Testing 535
Sensor Removal And Installation 536
Wheel Alignment (Field Adjustment) 538
Wheel Alignment (Calibration) 542
SERVICE PC (LAPTOP COMPUTER) 547
Connecting The Service PC To Remote Start Tool 547
CALIBRATION 549
Lift And Tilt Calibration Procedure 549
Hydrostatic Pump Calibration 551
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE 558
Controls Identification Chart 558
FLYWHEEL RPM SENSOR 561
Adjustment 561
ENGINE SERVICE 563
TROUBLESHOOTING 567
Chart 567
ENGINE SPEED CONTROL 569
Removal 569
Disassembly 571
Speed Control Cable 572
MUFFLER 573
Removal And Installation 573
AIR CLEANER 575
Housing Removal And Installation 575
RADIATOR 577
Removal And Installation 577
Mount Removal (Early Loaders) 579
Mount Removal (Later Loaders) 579
COOLING FAN 581
Drive Tension Pulley Removal And Installation 581
Gearbox/Blower Housing Removal And Installation 582
Blower Removal And Installation 585
Gearbox Parts Identification 586
Gearbox Disassembly 587
Gearbox Assembly 592
Gearbox, Checking Backlash 597
ENGINE 601
Removal And Installation 601
Mount Replacement 608
Removal And Installation Tools 609
FLYWHEEL AND HOUSING 611
Flywheel Removal And Installation 611
Ring Gear Removal And Installation 611
Flywheel Housing Removal And Installation 611
RECONDITIONING THE ENGINE 613
Engine Tools Identification Chart 613
Compression Pressure 618
Cylinder Head Clearance 618
Valve Cover, Injector Nozzle And Seal Removal And Installation 619
Checking Nozzle Injection Pressure 621
Nozzle Spraying Condition 622
Valve Seat Tightness 622
Rocker Arm And Push Rod Disassembly And Assembly 623
Valve Clearance 623
Cylinder Head And Tappet Disassembly And Assembly 624
Selecting Cylinder Head Gasket Disassembly And Assembly 625
Valve Disassembly And Assembly 627
Engine Timing (TDC) 627
Injection Pump Housing Removal 628
Injection Pump Governor Housing Removal And Installation 631
Injection Pump Governor Fork Lever Removal And Installation 633
Injection Pump Governor Lever Removal And Installation 633
Injection Pump Stop Lever Removal And Installation 634
Injection Pump Fuel Camshaft And Governor Weight Removal And Installation 634
Injection Pump Removal and Installation 636
Injection Pump Housing Installation 643
Injection Pump Timing 646
Fan Drive Pulley Disassembly And Assembly 648
Water Pump Disassembly And Assembly 649
Oil Cooler And Water Pipe Disassembly And Assembly 649
Gearcase Cover Disassembly And Assembly 650
Idle Gear And Camshaft Disassembly And Assembly 651
Oil Pan And Oil Strainer Disassembly And Assembly 651
Connecting Rod Cap Disassembly And Assembly 652
Piston Disassembly And Assembly 652
Piston Ring And Connecting Rod Disassembly And Assembly 653
Flywheel And Crankshaft Disassembly And Assembly 654
Bearing Case Cover Disassembly And Assembly 655
Flywheel Housing Disassembly And Assembly 656
Crankcase No 2 Disassembly And Assembly 656
Crankcase No 1 And No 2 Disassembly And Assembly 657
Crankshaft Disassembly And Assembly 657
Cylinder Head Surface Flatness 658
Cylinder Head Flaw 659
Valve Recessing 659
Valve Lapping 660
Clearance Between Valve Stem And Valve Guide 660
Replacing Valve Guide 661
Correcting Valve And Valve Seat 661
Free Length And Tilt Of Valve Spring 662
Valve Spring Setting Load 662
Oil Clearance Between Rocker Arm Shaft And Bearing 663
Oil Clearance Between Tappet And Tappet Guide Bore 663
Timing Gear Backlash 664
Idler Gear Side Clearance 664
Camshaft Side Clearance 665
Camshaft Alignment 665
Cam Height 665
Oil Clearance Between Idler Gear Shaft And Idler Gearing Bushing 666
Replacing Idler Gear Bushing 667
Piston Pin Bore I D 668
Oil Clearance Between Piston Pin And Small End Bushing 668
Replacing Small End Bushing 669
Clearance Between Piston Ring And Groove 669
Piston Ring Gap 670
Connecting Rod Alignment 670
Crankshaft Side Clearance 671
Crankshaft Alignment 672
Oil Clearance Between Crankpin And Crankpin Bearing 672
Oil Clearance Between Crankshaft Journal And Crankshaft Bearing 674
Replacing Crankshaft Sleeve 675
Cylinder Bore I D 675
Correcting Cylinder (Oversize +0 5 mm) 676
Engine Oil Pressure 676
Rotor Lobe Clearance 677
Clearance Between Outer Rotor And Pump Body 677
Clearance Between Rotor And Cover 677
Relief Valve 678
Thermostat Valve Opening Temperature 678
Radiator Water Leakage 678
Radiator Cap Air Leakage 679
Thermostat Assembly 679
Intake Air Heater 680
Air Cleaner, Intake Pipe, Inlet Pipe And Muffler 681
Oil Pipe 681
Turbocharger 682
HEATING, VENTILATION, AIR CONDITIONING 683
AIR CONDITIONING SYSTEM FLOW 686
Principals 686
Chart 687
COMPONENTS 689
Identification 689
SAFETY 693
Safety Equipment 693
REGULAR MAINTENANCE 695
Filter Elements Removal And Installation 695
Compressor Drive Belt Inspection 696
Cleaning The Condenser 697
BASIC TROUBLESHOOTING 699
Poor A/C Performance 699
Cleaning The A/C Evaporator Coil & Heater Coil 700
Compressor Drive Belt Inspection 700
Checking The Electrical System 701
Engine Coolant By-Passing The Heater Valve 709
Heater Valve Not Opening Or Closing 710
GENERAL AIR CONDITIONING SERVICE GUIDELINES 711
Compressor Oil 711
Compressor Oil Check 712
Component Replacement And Refrigeration Leaks 713
SYSTEM TROUBLESHOOTING CHART 715
Gauge Pressure Related Troubleshooting 716
Troubleshooting Tree 718
TEMPERATURE/PRESSURE 723
Chart 723
AIR CONDITIONING SERVICE 725
Chart 725
SYSTEM CHARGING AND RECLAMATION 727
Reclamation Procedure 727
Charging Procedure With A Manifold Gauge Set 729
Charging Procedure 730
COMPRESSOR 733
Removal And Installation 733
Compressor Clutch Disassembly 734
CONDENSER 739
Removal And Installation 739
RECEIVER/DRIER 741
Removal And Installation 741
PRESSURE RELIEF VALVE 743
Removal And Installation 743
PRESSURE SWITCH 745
Removal And Installation 745
EVAPORATOR/HEATER UNIT 747
Removal And Installation 747
Disassembly And Assembly 748
THERMOSTAT 749
Removal And Installation 749
EXPANSION VALVE 751
Removal And Installation 751
EVAPORATOR 753
Removal And Installation 753
HEATER COIL 755
Removal And Installation With A/C 755
Removal And Installation Without A/C 757
BLOWER FAN 759
Removal And Installation 759
Disassembly And Assembly 760
Wire Connector Removal and Installation 762
HEATER VALVE 765
Removal and Installation 765
Disassembly And Assembly 766
SPECIFICATIONS 769
A300 LOADER SPECIFICATIONS 771
Machine Dimensions 771
Performance 772
Controls 772
Engine 772
Hydraulic System 773
Electrical 773
Drive System 774
Capacities 774
Tires 774
ENGINE SPECIFICATIONS 775
General 775
Fuel System 775
Valve And Valve Timing 775
Valve Spring 776
Piston And Piston Ring 776
Connecting Rod 776
Cylinder Head 777
Crankshaft 777
Cylinder Bore 777
Oil Pump 777
Rocker Arm 778
Tappet 778
Camshaft 778
Thermostat 778
Timing Gear 779
Intake Air Heater 779
Turbocharger Compressor Shaft 779
TORQUE SPECIFICATIONS FOR BOLTS 781
Torque For General SAE Bolts 781
Torque For General Metric Bolts 782
Torque For Kubota Metric Engine Bolts 783
Tightening Torques For General Use Screws, Bolts And Nuts 783
HYDRAULIC CONNECTION SPECIFICATIONS 785
O-ring Face Seal Connection 785
Straight Thread O-ring Fitting 786
Tubelines And Hoses 786
Flare Fitting 786
O-ring Flare Fitting 787
Port Seal Fitting 789
HYDRAULIC FLUID SPECIFICATIONS 791
Specifications 791
CONVERSIONS 793
Decimal And Millimeter Equivalents 793
SMR 795
A300-1 795
A300-2 797
A300-3 799
A300-4 801
A300-5 803

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