Bobcat A300 Turbo Loader Service Manual 6901756 – PDF DOWNLOAD

Description

Bobcat A300 Turbo Loader Service Manual 6901756 – PDF DOWNLOAD

FILE DETAILS:

Bobcat A300 Turbo Loader Service Manual 6901756 – PDF DOWNLOAD

Language : English
Pages : 772
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat A300 Turbo Loader Service Manual 6901756 – PDF DOWNLOAD

S/N 521111001 & Above
S/N 521211001 & 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 Loader Service Manual 6901756 – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrestor Exhaust System 13
Welding And Grinding 14
Fire Extinguishers 14
SERIAL NUMBER LOCATION 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
BOBCAT LOADER INDENTIFICATION 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 43
Removing Air From The Fuel System 44
Fuel Lift Pump Strainer 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 48
Steering Filter Replacement 48
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 77
Troubleshooting 81
Tighten Procedures 82
CYLINDER (LIFT) 83
Checking 83
Removal And Installation 83
Parts Identification 85
Disassembly 86
Assembly 87
CYLINDER (TILT) 91
Checking 91
Removal And Installation 91
Base Pin Removal And Installation 93
Parts Identification 94
Disassembly 95
Assembly 96
CYLINDER (POWER BOB-TACH) 99
Checking 99
Removal And Installation 100
Parts Identification 101
Disassembly 102
Assembly 103
CYLINDER (STEERING) 107
Removal (Front) 107
Removal (Rear) 110
MAIN RELIEF VALVE 113
Checking The Main Relief Valve At Front Auxiliary Hydraulics 113
Removal and Installation 114
Adjustment 115
HYDRAULIC CONTROL VALVE 117
Actuator Removal And Installation (In Loader) 117
Removal And Installation 119
Actuator Removal And Installation (Out Of Loader) 123
BICS™ Valve Removal And Installation 124
BICS™ Valve Lift Arm Bypass Orifice Removal And Installation 125
BICS™ Valve Check Valve Removal And Installation 125
BICS™ Valve Lock Valve Removal And Installation 126
BICS™ Valve Solenoid Removal And Installation 127
BICS™ Valve Solenoid Testing 128
Identification Chart 129
Lift Base End Restrictor 130
Load Check Valve 130
Main Relief Valve 131
Port Relief Valve 132
Anti-Cavitation Valve / Port Relief Valve 133
Anti-Cavitation Valve 134
Lift Spool Removal And Installation 134
Tilt Spool Removal And Installation 135
Lift And Tilt Spool Disassembly And Assembly 136
Auxiliary Spool Removal And Installation 137
Auxiliary Electric Solenoid Disassembly And Assembly 138
Port-Auxiliary Section Disassembly 139
Cleaning And Inspection 140
LIFT ARM BYPASS CONTROL VALVE 141
Inspecting 141
Additional Inspection For Loaders W/ Advanced Hand Controls 141
Removal And Installation 141
Disassembly And Assembly 142
HYDRAULIC PUMP 143
Checking The Output Of The Auxiliary Pump 143
Checking The Output Of The Steering Pump 144
Removal And Installation 145
Parts Identification 148
Disassembly And Assembly 149
HYDRAULIC / HYDROSTATIC FILTER 157
Housing Removal And Installation 157
Mount Removal And Installation 158
HYDRAULIC FLUID RESERVOIR 159
Fluid Removal 159
Removal And Installation 159
Hydraulic Fluid Screen 162
BUCKET POSITION VALVE 163
Solenoid Removal And Installation 163
Solenoid Testing 163
Removal And Installation 164
Disassembly And Assembly 164
REAR AUXILIARY DIVERTER VALVE (EARLY MODELS) 167
Removal and Installation 167
REAR AUXILIARY DIVERTER VALVE (EARLY MODELS) (CONT’D) 168
REAR AUXILIARY DIVERTER VALVE (EARLY MODELS) (CONT’D) 169
Disassembly and Assembly 169
Inspection 169
Solenoid Testing 170
Assembly 170
REAR AUXILIARY DIVERTER (LATER MODELS) 171
Removal and Installation 171
REAR AUXILIARY DIVERTER (LATER MODELS) (CONT’D) 172
Disassembly And Assembly 173
Solenoid Testing 178
Inspection 178
POWER BOB-TACH BLOCK (EARLY MODELS) 179
Removal And Installation 179
Disassembly And Assembly 182
POWER BOB-TACH BLOCK (LATER MODELS) 191
Removal And Installation 191
Disassembly And Assembly 194
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK 199
Removal and Installation 199
Disassembly And Assembly 199
HYDROSTATIC SYSTEM 201
HYDROSTATIC SYSTEM INFORMATION 203
Troubleshooting Chart 203
Replenishing Valve Function 204
HYDROSTATIC MOTOR 205
Removal And Installation 205
Parts Identification 207
Disassembly 209
Inspection 215
Assembly 217
HYDROSTATIC MOTOR CARRIER 223
Removal And Installation 223
Parts Identification 224
Assembly 227
CHARGE PRESSURE 231
Hydrostatic Charge Pressure Sender 231
HYDROSTATIC PUMP 233
Pump Controller Removal And Installation 233
Hydrostatic Pump Calibration 236
Removal And Installation 240
Parts Identification (Right Half) 243
Parts Identification (Left Half) 245
System Check Relief Valves (High Pressure Relief, Charge Check & Bypass Valve) 247
Charge Relief Valve 248
Pump Separation 250
Shaft Seal And Shaft Replacement 251
Shaft Seal And Shaft Installation 253
Charge Pump Removal 255
Charge Pump Inspection 257
Charge Pump Installation 258
Disassembly 260
Inspection 267
Assembly 271
Pump Neutral Adjustment 280
Pump Controller Neutral Adjustment 283
DRIVE BELT 287
Shield Removal And Installation 287
Adjustment 287
Replacement 287
Tensioner Pulley Removal And Installation 288
Tensioner Pulley Tension Spring 290
OIL COOLER (SEAL TO CONNECT) (STC) 291
Hydraulic Oil Cooler Removal And Installation 291
DRIVE SYSTEM 293
BRAKE 295
Block Removal And Installation 295
Block Disassembly And Assembly 296
STEERING BLOCK 301
Wiring Diagram 301
Removal And Installation 303
Disassembly And Assembly 304
DRIVE COMPONENTS 313
Axle Seal Removal And Installation 313
Axle, Sprocket And Bearings Removal And Installation 314
Drive Chain Removal And Installation 319
CHAINCASE 321
Front Chaincase Cover Removal And Installation 321
Rear Chaincase Cover Removal And Installation 321
HUB 323
Removal 323
Installation 325
Disassembly 329
Inspection 332
Assembly 333
MAINFRAME 337
SEAT BAR 339
Removal And Installation 339
Assembling Components 340
Compression Spring Disassembly And Assembly 341
OPERATOR CAB 343
Gas Cylinder Removal And Installation (Early Models) 343
Gas Cylinder Removal And Installation (Later Models) 345
Gas Cylinder Bracket Disassembly And Assembly 347
Removal And Installation 347
OPERATOR SEAT 351
Removal And Installation 351
Seat Belt Removal And Installation 351
OPERATOR SEAT (SUSPENSION) 353
Removal And Installation 353
Slide Rail Removal And Installation 354
Cushion Removal And Installation 354
Back Removal And Installation 355
Shock Removal And Installation 356
BOB-TACH 357
Removal And Installation 357
Bob-Tach Lever And Wedge 359
POWER BOB-TACH 361
Removal And Installation 361
Power Bob-Tach Lever And Wedge 363
Pivot Pin Bushing And Seal Replacement 365
LIFT ARMS 367
Stabilizer Bar Removal And Installation 367
Link Removal And Installation 368
Removal And Installation 369
Installation Of Lift Arms 371
REAR GRILL 373
Removal And Installation 373
REAR DOOR 375
Removal And Installation 375
Adjusting The Rear Door Latch 376
FUEL TANK 377
Removal And Installation 377
Fuel Level Sender 378
CONTROL 379
Joystick Testing (Right & Left) 379
Joystick Removal (Right & Left) 380
Joystick Boot Removal (Right & Left) 381
Lever Assembly Removal (Right & Left) 381
CONTROL PANEL 383
Removal And Installation 383
INSIDE ACCESS PANEL 387
Panel Removal (Right) 387
Panel Removal (Left) 390
ELECTRICAL SYSTEM & ANALYSIS 391
ELECTRICAL SCHEMATICS 395
ELECTRICAL SYSTEM INFORMATION 399
Troubleshooting 401
Description 402
Fuse Location 403
Relay Switch Location 403
Solenoid Test 403
BATTERY 405
Removal And Installation 405
Servicing The Electrical System 407
Using A Booster Battery (Jump Starting) 408
ALTERNATOR 409
Adjusting The Alternator Belt 409
Alternator Identification 409
Charging System Check 410
Alternator Voltage Test 411
Low Voltage Test 411
High Voltage Test 412
Removal And Installation 412
Rectifier Continuity (Diode) Test 413
Alternator Regulator Test 414
Disassembly 415
Stator Continuity Test 415
Stator Ground Test 415
Rotor Continuity Test 416
Rotor Ground Test 416
Assembly 416
STARTER 417
Checking 417
Removal And Installation 417
Parts Identification 419
Disassembly And Assembly 420
Inspection And Repair 423
No Load Test 426
INSTRUMENT PANEL 427
Left Panel 427
Right Panel – (Standard) (With Key Switch) 428
Right Panel – (Deluxe) (With Keyless Start) 429
Right Panel Set Up Display Options (Deluxe) 430
Option and Field Accessory Panels (If Equipped) 434
Standard Panel Removal And Installation (Right Side) 436
Deluxe Panel Removal And Installation (Right Side) 437
Standard & Deluxe Panel Removal And Installation (Left Side) 438
LIGHTS 441
Front Removal And Installation 441
Rear Removal And Installation 442
BOBCAT 2001 CONTROLLER 443
Removal And Installation 443
Identification Chart 444
AWS CONTROLLER 447
Removal 447
Identification Chart 450
SPEED SENSOR 453
Testing 453
Removal 454
DIAGNOSTICS SERVICE CODES 457
Display 457
Number Codes List 459
STEERING SOLENOID 463
Removal 463
BICS™ SYSTEM 465
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 465
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 465
Inspecting The Seat Bar Sensor (Engine RUNNING) 465
Inspecting The Traction Lock (Engine RUNNING) 465
Troubleshooting Chart 466
Troubleshooting Guide 467
SEAT BAR SENSOR 469
Troubleshooting Chart 469
Test 470
Removal And Installation 471
BICS™ Circuit Test 472
TRACTION LOCK 473
Troubleshooting Chart 473
Description Of The Control System 474
Inspecting The Control System 474
WHEEL POSITION SENSORS 475
Operation 475
Wheel Alignment (Failed Sensor) 476
Testing 477
Sensor Removal And Installation 478
Wheel Alignment (Field Adjustment) 480
Wheel Alignment (Calibration) 484
SERVICE PC (LAPTOP COMPUTER) 489
Connecting The Service PC To Remote Start Tool 489
LIFT AND TILT ACTUATOR CALIBRATION 491
Procedure 491
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE 494
Controls Identification Chart 494
ENGINE SERVICE 497
TROUBLESHOOTING 499
Chart 499
ENGINE SPEED CONTROL 501
Removal 501
Disassembly 503
Speed Control Cable 504
MUFFLER 507
Removal And Installation 507
AIR CLEANER 509
Housing Removal And Installation 509
RADIATOR 511
Removal And Installation 511
COOLING FAN 513
Drive Tension Pulley Removal And Installation 513
Gearbox / Blower Housing Removal And Installation 514
Blower Removal And Installation 517
Gearbox Parts Identification 518
Gearbox Disassembly 519
Gearbox Assembly 524
Gearbox, Checking Backlash 529
ENGINE COMPONENTS AND TESTS 533
Engine Compression, Checking 533
Glow Plug, Checking 535
Fuel Shut-Off Solenoid Checking 536
Fuel Shut-Off Solenoid Removal And Installation 537
Fuel Injection Pump Removal 537
Fuel Injection Pump Timing 539
Fuel Injection Pump Installation 540
Fuel Injector Removal And Installation 542
Fuel Injector, Checking 543
Fuel Injector Disassembly 543
Fuel Injector Assembly 545
Timing Belt Inspection 547
Timing Belt Removal 547
Timing Belt Installation 549
Timing Belt, Replacement In The Loader 553
Valve Clearance Adjustment 559
Valve Timing, Checking 560
Thermostat, Oil Pressure Control Valves & Heater Connections 562
ENGINE 565
Removal And Installation 565
Mount Replacement 574
FLYWHEEL AND HOUSING 575
Flywheel Removal And Installation 575
Ring Gear Removal And Installation 575
Flywheel Housing Removal And Installation 576
RECONDITIONING THE ENGINE 577
Deutz Engine Tools Identification Chart 577
Disassembly 578
Assembly 582
Cylinder, Checking 598
Camshaft Bearing, Checking 598
Camshaft Bearing, Removal And Installation 599
Control Rod Guide Bushing Removal 600
Control Rod Guide Bushing Installation 602
Rear Cover Seal Removal And Installation 606
Crankshaft, Checking 607
Connecting Rod, Checking 609
Piston, Checking 611
Piston Pin, Checking 612
Piston Rings Installation 613
Piston Installation On The Connecting Rod 614
Cylinder Head Disassembly 616
Valves, Checking 616
Valve Seats, Checking 617
Cylinder Head Assembly 618
Rocker Arm And Bracket, Checking 619
Front Cover Disassembly 620
Front Cover Assembly 625
Turbo Charger Removal and Installation 635
Crankshaft Gear Mounting Bolt Torque Procedure 637
HEATING, VENTILATION, AIR CONDITIONING 639
AIR CONDITIONING SYSTEM FLOW 642
Principals 642
Chart 643
COMPONENTS 645
Identification 645
SAFETY 649
Safety Equipment 649
REGULAR MAINTENANCE 651
Filter Elements Removal And Installation 651
Compressor Drive Belt Inspection 652
Cleaning The Condenser 653
BASIC TROUBLESHOOTING 655
Poor A/C Performance 655
Cleaning The A/C Evaporator Coil & Heater Coil 656
Receiver / Drier Sight Glass Inspection 658
Compressor Drive Belt Inspection 659
Checking The Electrical System 660
Engine Coolant Bypassing The Heater Valve 667
Heater Valve Not Opening Or Closing 668
GENERAL AIR CONDITIONING SERVICE GUIDELINES 669
Compressor Oil 669
Compressor Oil Check 670
Component Replacement And Refrigeration Leaks 671
SYSTEM TROUBLESHOOTING CHART 673
Gauge Pressure Related Troubleshooting 674
Troubleshooting Tree 676
TEMPERATURE / PRESSURE 681
Chart 681
AIR CONDITIONING SERVICE 683
Chart 683
SYSTEM CHARGING AND RECLAMATION 685
Reclamation Procedure 685
Charging Procedure With A Manifold Gauge Set 687
Charging Procedure 689
COMPRESSOR 691
Removal And Installation 691
Compressor Clutch Disassembly 692
CONDENSER 697
Removal And Installation 697
RECEIVER / DRIER 699
Removal And Installation 699
PRESSURE RELIEF VALVE 701
Removal and Installation 701
PRESSURE SWITCH 703
Removal And Installation 703
EVAPORATOR / HEATER UNIT 705
Removal And Installation 705
Disassembly And Assembly 707
THERMOSTAT 709
Removal And Installation 709
EXPANSION VALVE 711
Removal And Installation 711
EVAPORATOR 713
Removal And Installation 713
HEATER COIL 715
Removal And Installation With A/C 715
Removal And Installation Without A/C 716
HEATER / AC FAN 719
Removal And Installation 719
Disassembly And Assembly 720
Wire Connector Removal And Installation 722
HEATER VALVE 725
Removal And Installation 725
Disassembly And Assembly 726
SPECIFICATIONS 729
LOADER SPECIFICATIONS (A300) 731
Machine Dimensions 731
Performance 732
Controls 732
Engine 732
Hydraulic System 733
Electrical 733
Drive System 734
Capacities 734
Tires 734
ENGINE SPECIFICATIONS 735
General 735
Fuel System 735
Valve And Valve Guide And Seat Insert 735
Piston And Rings 736
Connecting Rod 736
Cylinder Head And Block 736
Crankshaft And Main Bearings 737
Camshaft And Bearings 737
Oil Pump 737
LOADER TORQUE 739
Specifications 739
TORQUE SPECIFICATIONS FOR BOLTS 743
Torque For General SAE Bolts 743
Torque For General Metric Bolts 744
Torque For Kubota Metric Engine Bolts 745
HYDRAULIC CONNECTION SPECIFICATIONS 747
O-ring Face Seal Connection 747
Straight Thread O-ring Fitting 748
Tubelines And Hoses 748
Flare Fitting 748
O-ring Flare Fitting 749
Port Seal Fitting 751
HYDRAULIC FLUID SPECIFICATIONS 753
Specifications 753
CONVERSIONS 755
Decimal And Millimeter Equivalents 755
Revision No: A300-1 757
Date: 24 May 2002 757
Product: Bobcat Loader 757
Model: A300 757
Manual No: 6901756 (3-02) 757
PARTS MANAGER 759
SERVICE MANAGER X 759
SALES MANAGER 759
Revision No: A300-2 759
Date: 30 October 2003 759
Product: Bobcat Loader 759
Model: A300 759
Manual No: 6901756 (3-02) 759
PARTS MANAGER 761
SERVICE MANAGER X 761
SALES MANAGER 761
Revision No: A300-3 761
Date: 8 December 2003 761
Product: Bobcat Loader 761
Model: A300 761
Manual No: 6901756 (3-02) 761
PARTS MANAGER 763
SERVICE MANAGER X 763
SALES MANAGER 763
Revision No: A300-4 763
Date: 4 May 2004 763
Product: Bobcat Loader 763
Model: A300 763
Manual No: 6901756 (3-02) 763
PARTS MANAGER 765
SERVICE MANAGER X 765
SALES MANAGER 765
Revision No: A300-5 765
Date: 23 March 2006 765
Product: Bobcat Loader 765
Model: A300 765
Manual No: 6901756 (3-02) 765
PARTS MANAGER 767
SERVICE MANAGER X 767
SALES MANAGER 767
Revision No: A300-6 767
Date: 21 March 2008 767
Product: Bobcat Loader 767
Model: A300 767
Manual No: 6901756 (3-08) 767
PARTS MANAGER 769
SERVICE MANAGER X 769
SALES MANAGER 769
Revision No: A300-7 769
Date: 23 July 2010 769
Product: Bobcat Loader 769
Model: A300 769
Manual No: 6901756 (7-10) 769
SMR 757
A300-1 757
A300-2 759
A300-3 761
A300-4 763
A300-5 765
A300-6 767
A300-7 769
A300-8 771

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