BOBCAT B300 B-Series loader Service Manual SN 573111001 PDF DOWNLOAD

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BOBCAT B300 B-Series loader Service Manual SN 573111001 PDF DOWNLOAD

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BOBCAT B300 B-Series loader Service Manual SN 573111001 PDF DOWNLOAD

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

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TABLE OF CONTENTS:

BOBCAT B300 B-Series loader Service Manual SN 573111001 PDF DOWNLOAD

MAINTENANCE SAFETY…………………………………….. 3
ALPHABETICAL INDEX…………………………………….. 5
CONTENTS……………………………………………… 7
FOREWORD………………………………………….. 8
SAFETY INSTRUCTIONS………………………………… 11
Fire Prevention………………………………… 13
SERIAL NUMBER LOCATION……………………………… 15
Loader Backhoe Serial Number…………………….. 15
Engine Serial Number……………………………. 15
DELIVERY REPORT……………………………………. 16
LOADER BACKHOE IDENTIFICATION……………………….. 17
SAFETY AND MAINTENANCE…………………………………. 19
LIFTING AND BLOCKING THE LOADER BACKHOE………………. 21
Procedure……………………………………… 21
APPROVED LIFT ARM SUPPORT DEVICE…………………….. 23
Installing The Approved Lift Arm Support Device……. 23
Removing The Approved Lift Arm Support Device……… 24
ENGINE COVER………………………………………. 25
TRANSPORTING THE LOADER BACKHOE……………………… 27
Procedure……………………………………… 27
TOWING THE LOADER BACKHOE…………………………… 29
Procedure……………………………………… 29
AXLE TOE-IN……………………………………….. 31
Procedure……………………………………… 31
SERVICE SCHEDULE…………………………………… 33
Chart…………………………………………. 33
AIR CLEANER SERVICE………………………………… 35
Replacing The Filter……………………………. 35
ENGINE COOLING SYSTEM………………………………. 37
Cleaning The Cooling System……………………… 37
Checking Coolant Level………………………….. 37
Coolant Replacement…………………………….. 37
FUEL SYSTEM……………………………………….. 39
Fuel Specifications…………………………….. 39
Filling The Fuel Tank…………………………… 39
Fuel Filter……………………………………. 39
Removing Air From The Fuel System………………… 41
ENGINE LUBRICATION SYSTEM…………………………… 43
Checking Engine Oil…………………………….. 43
Oil Chart……………………………………… 43
Replacing The Oil And Filter…………………….. 44
HYDRAULIC/HYDROSTATIC SYSTEM………………………… 47
Checking And Adding Fluid……………………….. 47
Cleaning The Oil Cooler/Radiator…………………. 48
Replacing Hydraulic/Hydrostatic Filter……………. 48
Replacing Hydraulic Fluid……………………….. 49
AXLES (FRONT AND REAR)……………………………… 51
Checking Oil Level (Planetary Carrier)……………. 51
Draining Oil (Planetary Carrier)…………………. 51
Checking Oil Level (Rear Axle)…………………… 52
Draining Oil (Rear Axle)………………………… 52
Checking Oil Level (Front Axle)………………….. 52
Draining Oil (Front Axle)……………………….. 52
BOOM LOCK PIN……………………………………… 53
Engaging And Disengaging The Pin…………………. 53
BOB-TACH HAND LEVER………………………………… 55
Inspection And Maintenance………………………. 55
ALTERNATOR BELT……………………………………. 57
Adjusting The Alternator Belt……………………. 57
LUBRICATING THE LOADER BACKHOE………………………. 59
TIRE MAINTENANCE…………………………………… 67
Wheel Nuts…………………………………….. 67
Mounting………………………………………. 67
Tire Pressure………………………………….. 67
HYDRAULIC SYSTEM………………………………………. 69
HYDRAULIC/HYDROSTATIC SCHEMATIC……………………… 73
HYDRAULIC SYSTEM INFORMATION………………………… 75
Troubleshooting………………………………… 78
Description……………………………………. 79
ARM CYLINDER………………………………………. 81
Checking………………………………………. 81
Removal And Installation………………………… 82
Parts Identification……………………………. 85
Disassembly……………………………………. 86
Assembly………………………………………. 88
BOOM CYLINDER……………………………………… 91
Checking………………………………………. 91
Removal And Installation………………………… 93
Parts Identification……………………………. 96
Disassembly……………………………………. 97
Assembly………………………………………. 99
SWING CYLINDER……………………………………..103
Checking……………………………………….103
Removal And Installation…………………………104
Parts Identification…………………………….106
Disassembly…………………………………….107
Assembly……………………………………….109
Bushing Removal And Installation………………….112
BUCKET CYLINDER…………………………………….113
Checking……………………………………….113
Removal And Installation…………………………115
Parts Identification…………………………….118
Disassembly…………………………………….119
Assembly……………………………………….121
STABILIZER CYLINDER…………………………………123
Checking……………………………………….123
Removal And Installation…………………………125
Parts Identification…………………………….127
Disassembly…………………………………….128
Assembly……………………………………….132
TILT CYLINDER………………………………………137
Checking……………………………………….137
Removal And Installation…………………………138
Parts Identification…………………………….140
Disassembly…………………………………….141
Assembly……………………………………….143
LIFT CYLINDER………………………………………145
Checking……………………………………….145
Removal And Installation…………………………146
Parts Identification…………………………….148
Disassembly…………………………………….149
Assembly……………………………………….151
STEERING CYLINDER (FRONT)……………………………155
Removal And Installation…………………………155
Parts Identification…………………………….159
Disassembly And Assembly…………………………160
Inspection……………………………………..163
STEERING CYLINDER (REAR)…………………………….165
Removal And Installation…………………………165
Parts Identification…………………………….168
Disassembly And Assembly…………………………169
Inspection……………………………………..172
MAIN RELIEF VALVE…………………………………..173
Description…………………………………….173
Testing………………………………………..173
Adjustment……………………………………..174
PORT RELIEF VALVE (BACKHOE CONTROL VALVE)……………..175
Testing And Adjusting (Arm Control)……………….175
Testing And Adjusting (Bucket Control)…………….176
Testing And Adjusting (Boom Control)………………178
Testing And Adjusting (Boom Swing Control)…………179
PORT RELIEF VALVE (LOADER CONTROL VALVE)………………181
Testing And Adjusting (Bucket Tilt)……………….181
Testing And Adjusting (Front Auxiliary)……………183
LOADER CONTROL VALVE………………………………..185
Removal And Installation…………………………185
Parts Identification…………………………….187
Disassembly And Assembly…………………………188
Inlet/Outlet Valve Section……………………….188
Lift Arm Valve Section…………………………..190
Tilt Valve Section………………………………194
Auxiliary Valve Section (Front)…………………..199
BACKHOE CONTROL VALVE……………………………….205
Removal And Installation…………………………205
Parts Identification…………………………….207
Disassembly And Assembly…………………………208
Inlet/Outlet Valve Section……………………….209
Arm Valve Section……………………………….211
Bucket Valve Section…………………………….214
Right Stabilizer Valve Section……………………218
Left Stabilizer Valve Section…………………….221
Boom Valve Section………………………………225
Boom Swing Valve Section…………………………228
Outlet Valve Section…………………………….231
HYDRAULIC FLUID RESERVOIR……………………………233
Removal And Installation…………………………233
Strainer Removal And Installation…………………235
HYDRAULIC FILTER HOUSING…………………………….237
Removal And Installation…………………………237
Disassembly…………………………………….238
Assembly……………………………………….239
HYDRAULIC FILTER……………………………………241
Removal And Installation…………………………241
GEAR PUMP………………………………………….243
Removal And Installation…………………………243
Parts Identification…………………………….244
Disassembly And Assembly…………………………245
Inspection……………………………………..248
STEERING PUMP………………………………………249
Removal And Installation…………………………249
Parts Identification…………………………….251
Disassembly…………………………………….252
Inspection……………………………………..261
Assembly……………………………………….261
STEERING VALVE……………………………………..271
Removal And Installation…………………………271
Wheel Alignment Procedure………………………..271
MASTER CYLINDER…………………………………….273
Removal And Installation…………………………273
Parts Identification…………………………….274
Disassembly And Assembly…………………………275
HYDROSTATIC SYSTEM……………………………………..277
HYDROSTATIC SYSTEM INFORMATION……………………….279
Troubleshooting Chart……………………………279
Replenishing Valve Function………………………280
OIL COOLER/RADIATOR…………………………………281
Description…………………………………….281
HYDROSTATIC DRIVE MOTOR……………………………..283
Removal And Installation…………………………283
Parts Identification…………………………….285
Disassembly…………………………………….287
Inspection……………………………………..302
Assembly……………………………………….305
HYDROSTATIC PUMP……………………………………321
Removal And Installation…………………………321
Parts Identification…………………………….324
Disassembly…………………………………….326
Inspection……………………………………..341
Assembly……………………………………….344
HYDROSTATIC PUMP TESTING…………………………….361
Hydrostatic Pump Work Sheet………………………361
Pump Testing……………………………………364
DRIVE SYSTEM…………………………………………..369
TROUBLESHOOTING…………………………………….371
Chart………………………………………….371
PARKING BRAKE HOUSING……………………………….373
Removal And Installation…………………………373
Parts Identification…………………………….374
Disassembly And Assembly…………………………375
SERVICE BRAKE………………………………………385
Description…………………………………….385
Bleeding The Brake Circuit……………………….385
REAR AXLE………………………………………….387
Removal………………………………………..387
Installation……………………………………390
AXLE AND DIFFERENTIAL (REAR)…………………………395
Troubleshooting Chart……………………………395
General Information……………………………..396
Planetary Carrier Parts Identification…………….397
Planetary Carrier Disassembly…………………….398
Planetary Carrier Inspection……………………..400
Wheel Hub/Brake Group Parts Identification…………401
Wheel Hub/Brake Group Disassembly…………………402
Steering Knuckle Parts Identification……………..408
Steering Knuckle Disassembly……………………..409
Axle Housing/Drive Axle Parts Identification……….411
Axle Housing/Drive Axle Disassembly……………….412
Differential Carrier Removal……………………..415
Differential Carrier Disassembly………………….416
Differential Carrier Disassembly (Cont’d)………….417
AXLE AND DIFFERENTIAL (REAR) (CONT’D)…………………418
Pinion Group Parts Identification…………………418
Pinion Group Disassembly…………………………419
Inspection……………………………………..421
Pinion Group Inspection………………………….424
Differential Parts Identification…………………425
Differential Disassembly…………………………425
Differential Inspection………………………….428
Differential Assembly……………………………430
Pinion Group Assembly……………………………433
Differential Carrier Assembly…………………….442
Differential Carrier Installation…………………445
Axle Housing/Drive Axle Assembly………………….446
Steering Knuckle Assembly………………………..449
Wheel Hub/Brake Group Assembly……………………452
Planetary Carrier Assembly……………………….457
STEERING ANGLE ADJUSTMENT (REAR AXLE)…………………461
Adjustment……………………………………..461
FRONT AXLE…………………………………………463
Removal………………………………………..463
Installation……………………………………465
Axle Pivot Bushing Removal And Installation………..466
AXLE AND DIFFERENTIAL (FRONT)………………………..469
Troubleshooting Chart……………………………469
General Information……………………………..470
Planetary Carrier Parts Identification…………….470
Planetary Carrier Disassembly…………………….471
Planetary Carrier Inspection……………………..473
Wheel Hub Parts Identification……………………474
Wheel Hub Disassembly……………………………475
Wheel Hub Inspection…………………………….478
Steering Knuckle Parts Identification……………..478
Steering Knuckle Disassembly……………………..479
Axle Housing/Drive Axle Parts Identification……….481
Axle Housing/Drive Axle Disassembly……………….482
Differential Carrier Removal……………………..485
Differential Carrier Disassembly………………….486
AXLE AND DIFFERENTIAL (FRONT) (CONT’D)………………..488
Pinion Group Parts Identification…………………488
Pinion Group Disassembly…………………………489
Pinion Group Inspection………………………….491
Differential Parts Identification…………………492
Differential Disassembly…………………………492
Differential Inspection………………………….495
Differential Assembly……………………………496
Pinion Group Assembly……………………………499
Differential Carrier Assembly…………………….505
Axle Housing/Drive Axle Assembly………………….510
Steering Knuckle Assembly………………………..513
Wheel Hub Assembly………………………………516
Planetary Carrier Assembly……………………….518
STEERING ANGLE ADJUSTMENT (FRONT AXLE)………………..521
Adjustment……………………………………..521
DRIVESHAFT…………………………………………523
Removal And Installation…………………………523
DROP BOX…………………………………………..525
Removal And Installation…………………………525
Parts Identification…………………………….528
Disassembly…………………………………….530
Inspection……………………………………..535
Assembly……………………………………….537
BRAKE PEDAL ASSEMBLY………………………………..545
Removal And Installation…………………………545
MAIN FRAME…………………………………………….549
OPERATOR CANOPY…………………………………….551
Removal And Installation…………………………551
ENCLOSED CAB……………………………………….557
Not Available At Time Of Print……………………557
OPERATOR SEAT………………………………………559
Removal And Installation…………………………559
FLOOR PANELS……………………………………….561
Front Panel Removal And Installation………………561
Rear Panel Removal And Installation……………….561
Front Right Panel Removal And Installation…………562
Front Left Panel Removal And Installation………….562
GRILL……………………………………………..563
Removal And Installation…………………………563
GRILL FRAME………………………………………..565
Removal And Installation…………………………565
ENGINE SIDE COVERS………………………………….567
Removal And Installation…………………………567
FENDER…………………………………………….569
Removal And Installation…………………………569
ENGINE COVER……………………………………….571
Removal And Installation…………………………571
FUEL TANK………………………………………….573
Removal And Installation…………………………573
Screen Removal And Installation…………………..575
LIFT ARMS………………………………………….577
Removal And Installation…………………………577
BOB-TACH…………………………………………..583
Removal And Installation…………………………583
Bob-Tach Lever And Wedge…………………………584
Pivot Pin Bushing Removal And Installation…………586
ARM……………………………………………….587
Removal And Installation…………………………587
Arm Pivot Bushing Removal And Installation…………589
BOOM………………………………………………591
Removal And Installation…………………………591
Boom Pivot Bushing Removal And Installation………..592
SWING FRAME………………………………………..593
Removal And Installation…………………………593
X-CHANGE™………………………………………….595
Removal And Installation…………………………595
BUCKET…………………………………………….597
Backhoe Bucket Teeth Removal And Installation………597
Loader Bucket Teeth Removal And Installation……….597
LIFT ARM STABILIZER…………………………………599
Removal And Installation…………………………599
CENTER FLOOR PANEL………………………………….601
Removal And Installation…………………………601
STABILIZER…………………………………………605
Removal And Installation…………………………605
ELECTRICAL SYSTEM AND ANALYSIS…………………………..607
ELECTRICAL SCHEMATIC………………………………..609
ELECTRICAL SYSTEM INFORMATION………………………..611
Troubleshooting Chart……………………………611
Description…………………………………….612
Fuse And Relay Location………………………….612
Relay Location………………………………….612
BATTERY……………………………………………613
Removal And Installation…………………………613
Servicing The Electrical System…………………..614
Using A Booster Battery (Jump Starting)……………615
ALTERNATOR…………………………………………617
Adjusting The Alternator Belt…………………….617
Description…………………………………….617
Tests………………………………………….618
Alternator Output Test…………………………..618
Full Field Test…………………………………619
Alternator Regulator Test………………………..619
Alternator Regulator Test With Voltmeter…………..620
Alternator Removal And Installation……………….621
Parts Identification…………………………….622
Pulley Removal And Installation…………………..623
Disassembly And Assembly…………………………624
Rotor Continuity Test……………………………627
Stator Continuity Test…………………………..627
Rectifier Continuity (Diode) Test…………………628
Brush Length……………………………………628
STARTER……………………………………………629
Removal And Installation…………………………629
Checking The Starter In The Loader………………..629
Parts Identification…………………………….631
Disassembly…………………………………….632
Inspection And Repair……………………………637
No Load Test……………………………………641
Assembly……………………………………….642
FRONT LIGHTS……………………………………….649
Bulb Removal And Installation…………………….649
Housing Removal And Installation………………….651
TURN INDICATOR LIGHTS (FRONT)………………………..653
Bulb Removal And Installation…………………….653
TURN INDICATOR LIGHTS (REAR)…………………………655
Bulb Removal And Installation…………………….655
CAB LIGHTS…………………………………………657
Bulb Removal And Installation…………………….657
Housing Removal And Installation………………….659
FUEL LEVEL SENDER…………………………………..661
Removal And Installation…………………………661
INSTRUMENT PANEL……………………………………663
Removal And Installation…………………………663
ENGINE SERVICE…………………………………………665
TROUBLESHOOTING…………………………………….667
Chart………………………………………….667
ENGINE SPEED CONTROL………………………………..669
Removal And Installation…………………………669
Cable And Rod Removal And Installation…………….670
TRAVEL PEDAL……………………………………….673
Removal And Installation…………………………673
MUFFLER……………………………………………677
Removal And Installation…………………………677
AIR CLEANER………………………………………..679
Removal And Installation…………………………679
OIL COOLER/RADIATOR…………………………………681
Removal And Installation…………………………681
Disassembly…………………………………….683
Inspection……………………………………..684
Assembly……………………………………….684
ENGINE COMPONENTS AND TESTING………………………..687
Engine Compression Checking………………………687
Glow Plugs Removal And Installation……………….688
Checking The Glow Plug…………………………..689
Fuel Shut-off Solenoid Removal And Installation…….690
Fuel Injection Pump Check………………………..691
Fuel Injection Pump Removal And Installation……….692
Fuel Injection Pump Timing……………………….695
Fuel Injector Nozzles Removal And Installation……..697
Fuel Injector Nozzle Check……………………….699
Valve Clearance Adjustment……………………….700
ENGINE…………………………………………….701
Removal And Installation…………………………701
Mount Replacement……………………………….705
RECONDITIONING THE ENGINE……………………………707
Cylinder Head Removal And Installation…………….707
Cylinder Head Disassembly And Assembly…………….710
Cylinder Head Servicing………………………….711
Cylinder Head Top Clearance………………………711
Valve Guide Checking…………………………….712
Reconditioning The Valve And Valve Seat……………714
Valve Spring……………………………………715
Rocker Arm And Shaft Checking…………………….716
Timing Gearcase Cover Removal And Installation……..716
Idler Gear And Camshaft Removal And Installation……719
Camshaft Servicing………………………………720
Idler Gear And Shaft Servicing……………………721
Timing Gears Checking Backlash……………………722
Fuel Camshaft Removal And Installation…………….722
Fuel Camshaft Governor…………………………..723
Crankshaft Gear Removal And Installation…………..723
Oil Pump Removal And Installation…………………724
Oil Pump Service………………………………..724
Checking Engine Oil Pressure……………………..725
Valve Tappets…………………………………..726
Piston And Connecting Rod Removal And Installation….726
Piston And Connecting Rod Servicing……………….728
Connecting Rod Alignment…………………………730
Crankshaft And Bearings Removal And Installation……731
Crankshaft And Bearings Servicing…………………733
Cylinder Bore Checking…………………………..736
Water Pump Removal And Installation……………….736
Water Pump Disassembly And Assembly……………….737
Fan Removal And Installation……………………..738
FLYWHEEL HOUSING……………………………………739
Removal And Installation…………………………739
FLYWHEEL…………………………………………..741
Removal And Installation…………………………741
Ring Gear Removal And Installation………………..741
DRIVE COUPLER………………………………………743
Removal And Installation…………………………743
SPECIFICATIONS…………………………………………745
LOADER SPECIFICATIONS……………………………….747
Loader Backhoe Dimensions………………………..747
Loader Performance………………………………748
Backhoe Performance……………………………..748
Controls……………………………………….748
Engine…………………………………………748
Drive System……………………………………748
Electrical……………………………………..749
Tires………………………………………….749
Capacities……………………………………..749
ENGINE SPECIFICATIONS……………………………….751
Cylinder Head…………………………………..751
Valves…………………………………………751
Valve Springs…………………………………..752
Valve Timing……………………………………752
Rocker Arms…………………………………….752
Camshaft……………………………………….752
Cylinders………………………………………752
Tappet…………………………………………752
Piston Rings……………………………………753
Pistons………………………………………..753
Crankshaft……………………………………..753
Oil Pump……………………………………….753
Thermostat……………………………………..754
Connecting Rods…………………………………754
Timing Gear…………………………………….754
Cylinder Liner………………………………….754
Engine Bolt Torque………………………………755
BACKHOE LOADER TORQUE……………………………….757
Specifications………………………………….757
TORQUE SPECIFICATIONS FOR BOLTS………………………759
Torque For General Metric Bolts…………………..759
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS…………….761
Specifications………………………………….761
CONVERSIONS………………………………………..763
Decimal And Millimeter Equivalents………………..763
U.S. To Metric Conversion………………………..763
SMR…………………………………………………..765
B300-1…………………………………………….765
B300-2…………………………………………….767
B300-3…………………………………………….769
B300-4 ……………………………………………771

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DESCRIPTION:

BOBCAT B300 B-Series loader Service Manual SN 573111001 PDF DOWNLOAD

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.

A general inspection of the following items must be made after the loader has had service or repair:

1. Check that ROPS mounting hardware is tightened and is Bobcat approved.
2. The seat belt must be correctly installed, functional and in good condition.
3. Check lift arm support device, replace if damaged.
4. Machine signs must be legible and in the correct location.
5. Foot pedal must return to neutral.
6. Check for correct function of the work lights.
7. The parking brake must function correctly.
8. Enclosure door latches must open and close freely.
9. Bob-Tach wedges and linkages must function correctly and be in good condition.
10. Safety treads must be in good condition.
11. Check for correct function of indicator lamps (Optional on some models).
12. Check hydraulic fluid level, engine oil level, and fuel supply.
13. Inspect for fuel, oil, or hydraulic fluid leaks.
14. Lubricate the loader backhoe.
15. Check the condition of the battery and cables.
16. Inspect the air cleaner for damage or leaks. Check the condition of the element.
17. Check the electrical charging system.
18. Check tires for wear and pressure.
19. Inspect for loosen or broken parts or connections.
20. Operate the loader and check all functions.
21. Check for any field modification not completed.
22. Recommend to the owner that all necessary corrections be made before the machine is returned to service.

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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