BOBCAT B300 Loader Service Manual SN 571711001 PDF DOWNLOAD

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BOBCAT B300 SN 571711001 Service Manual PDF DOWNLOAD

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BOBCAT B300 SN 571711001 Service Manual PDF DOWNLOAD 

Language : English
Pages : 628
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

BOBCAT B300 SN 571711001 Service Manual 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……………………………………. 15
BOBCAT LOADER IDENTIFICATION………………………… 16
SAFETY AND MAINTENANCE…………………………………. 17
LIFTING AND BLOCKING THE LOADER BACKHOE………………. 19
Procedure……………………………………… 19
LIFT ARM SUPPORT DEVICE…………………………….. 21
Installing The Lift Arm Support Device……………. 21
Removing The Lift Arm Support Device……………… 22
ENGINE COVER………………………………………. 23
TRANSPORTING THE LOADER BACKHOE……………………… 25
Procedure……………………………………… 25
TOWING THE LOADER BACKHOE…………………………… 27
Procedure……………………………………… 27
AXLE TOE-IN……………………………………….. 29
Adjustment…………………………………….. 29
SERVICE SCHEDULE…………………………………… 31
Chart…………………………………………. 31
AIR CLEANER SERVICE………………………………… 33
Replacing Filter Element………………………… 33
ENGINE COOLING SYSTEM………………………………. 35
Coolant Replacement…………………………….. 35
FUEL SYSTEM……………………………………….. 37
Fuel Specifications…………………………….. 37
Filling The Fuel Tank…………………………… 37
Fuel Filter……………………………………. 38
ENGINE LUBRICATION SYSTEM…………………………… 39
Checking Engine Oil…………………………….. 39
Oil Chart……………………………………… 39
Replacing Oil And Filter………………………… 40
HYDRAULIC/HYDROSTATIC SYSTEM………………………… 43
Checking And Adding Fluid……………………….. 43
Cleaning The Cooler…………………………….. 43
Replacing Hydraulic/Hydrostatic Filter……………. 44
Replacing Hydraulic Fluid……………………….. 45
REAR AXLE…………………………………………. 47
Checking Oil Level……………………………… 47
Draining Oil…………………………………… 47
FRONT AXLE………………………………………… 48
Checking Oil Level……………………………… 48
Draining Oil…………………………………… 48
BACKHOE BOOM LOCK………………………………….. 49
Disengaging The Boom Lock……………………….. 49
Engaging Boom Lock……………………………… 50
BOB-TACH HAND LEVER………………………………… 51
Inspection And Maintenance………………………. 51
ALTERNATOR BELT……………………………………. 53
Adjusting The Alternator Belt……………………. 53
LUBRICATING THE LOADER BACKHOE………………………. 55
TIRE MAINTENANCE…………………………………… 63
Wheel Nuts…………………………………….. 63
Mounting………………………………………. 63
Tire Pressure………………………………….. 63
HYDRAULIC SYSTEM………………………………………. 65
HYDRAULIC/HYDROSTATIC SCHEMATICS…………………….. 69
HYDRAULIC SYSTEM INFORMATION………………………… 71
Troubleshooting………………………………… 75
Description……………………………………. 76
ARM CYLINDER………………………………………. 77
Checking………………………………………. 77
Removal And Installation………………………… 79
Parts Identification……………………………. 81
Disassembly……………………………………. 82
Assembly………………………………………. 85
BOOM CYLINDER……………………………………… 89
Checking………………………………………. 89
Removal And Installation………………………… 90
Parts Identification……………………………. 92
Disassembly……………………………………. 93
Assembly………………………………………. 96
SWING CYLINDER…………………………………….. 99
Removal And Installation………………………… 99
Bushing Removal And Installation………………….100
Parts Identification (Left Side)………………….101
Parts Identification (Right Side)…………………102
Disassembly…………………………………….103
Assembly……………………………………….106
BUCKET CYLINDER…………………………………….109
Checking……………………………………….109
Removal And Installation…………………………111
Parts Identification…………………………….113
Disassembly…………………………………….114
Assembly……………………………………….117
STABILIZER CYLINDER…………………………………121
Checking……………………………………….121
Removal And Installation…………………………123
TILT CYLINDER………………………………………127
Checking……………………………………….127
Removal And Installation…………………………128
Parts Identification (Left Side)………………….129
Parts Identification (Right Side)…………………130
Disassembly…………………………………….131
Assembly……………………………………….134
LIFT CYLINDER………………………………………137
Checking……………………………………….137
Removal And Installation…………………………138
Parts Identification (Left Side)………………….140
Parts Identification (Right Side)…………………141
Disassembly…………………………………….142
Assembly……………………………………….145
STEERING CYLINDER (FRONT)……………………………149
Removal And Installation…………………………149
Parts Identification…………………………….153
Disassembly And Assembly…………………………154
Inspection……………………………………..157
STEERING CYLINDER (REAR)…………………………….159
Removal And Installation…………………………159
Parts Identification…………………………….162
Disassembly And Assembly…………………………163
Inspection……………………………………..166
MAIN RELIEF VALVE…………………………………..167
Testing The Main Relief Valve…………………….167
Adjustment……………………………………..168
PORT RELIEF VALVE (BACKHOE CONTROL VALVE)……………..169
Testing And Adjusting (Arm Control)……………….169
Testing And Adjusting (Boom Control)………………171
Testing And Adjusting (Boom Swing Control)…………173
LOADER CONTROL VALVE………………………………..175
Removal And Installation…………………………175
Disassembly And Assembly…………………………176
Inlet/Outlet Valve Section……………………….177
Lift Arm Valve Section…………………………..179
Tilt Valve Section………………………………183
Auxiliary Valve Section (Front)…………………..187
Auxiliary Valve Section (Rear)……………………192
BACKHOE CONTROL VALVE……………………………….199
Removal And Installation…………………………199
Parts Identification…………………………….201
Disassembly And Assembly…………………………202
Inlet/Outlet Valve Section……………………….204
Arm Valve Section……………………………….206
Tilt Valve Section………………………………209
Right Stabilizer Valve Section……………………212
Left Stabilizer Valve Section…………………….215
Boom Valve Section………………………………219
Boom Swing Valve Section…………………………222
Outlet Valve Section…………………………….225
HYDRAULIC FLUID RESERVOIR……………………………227
Removal And Installation…………………………227
Filter Removal And Installation…………………..229
HYDRAULIC FILTER HOUSING…………………………….231
Removal And Installation…………………………231
Disassembly…………………………………….232
Assembly……………………………………….233
GEAR PUMP………………………………………….235
Removal And Installation…………………………235
Parts Identification…………………………….236
Disassembly And Assembly…………………………237
Inspection……………………………………..239
STEERING PUMP………………………………………241
Removal And Installation…………………………241
Parts Identification…………………………….243
Disassembly…………………………………….244
Inspection……………………………………..253
Assembly……………………………………….253
STEERING VALVE……………………………………..263
Removal And Installation…………………………263
Adjustment……………………………………..264
STEERING VALVE……………………………………..265
Removal And Installation…………………………265
Adjustment……………………………………..266
HYDROSTATIC SYSTEM……………………………………..267
HYDROSTATIC SYSTEM INFORMATION……………………….269
Troubleshooting Chart……………………………269
Replenishing Valve Function………………………270
OIL COOLER…………………………………………271
Disassembly…………………………………….271
Inspection……………………………………..272
Assembly……………………………………….272
HYDROSTATIC DRIVE MOTOR……………………………..275
Removal And Installation…………………………275
Disassembly…………………………………….277
Inspection……………………………………..290
Assembly……………………………………….293
HYDROSTATIC PUMP……………………………………307
Removal And Installation…………………………307
Disassembly…………………………………….309
Inspection……………………………………..330
Assembly……………………………………….332
HYDROSTATIC TESTING…………………………………353
Pump Adjustment…………………………………353
Operation Test – Creep Test:……………………..355
Operation Test – Torque Limiter Test:……………..355
DRIVE SYSTEM…………………………………………..357
PARKING BRAKE………………………………………361
Lever Removal And Installation……………………361
Cable Removal And Installation……………………363
Adjustment……………………………………..364
PARKING BRAKE………………………………………365
Lever Removal And Installation……………………365
Cable Removal And Installation……………………367
Adjustment……………………………………..368
PARKING BRAKE HOUSING……………………………….369
Removal And Installation…………………………369
Parts Identification…………………………….370
Disassembly And Assembly…………………………371
REAR AXLE………………………………………….381
Removal………………………………………..381
Installation……………………………………384
FRONT AXLE…………………………………………389
Removal………………………………………..389
Installation……………………………………391
Installation……………………………………391
Axle Pivot Bushing Removal And Installation………..393
DRIVESHAFT…………………………………………395
Removal And Installation…………………………395
DROP BOX…………………………………………..397
Removal And Installation…………………………397
Parts Identification…………………………….400
Disassembly…………………………………….402
Inspection……………………………………..407
Assembly……………………………………….409
MAIN FRAME…………………………………………….417
OPERATOR CANOPY…………………………………….419
Removal And Installation…………………………419
ENCLOSED CAB……………………………………….425
Not Available At Time Of Printing…………………425
OPERATOR SEAT………………………………………427
Removal And Installation…………………………427
FLOOR PANELS……………………………………….429
Front Panel Removal And Installation………………429
Rear Panel Removal And Installation……………….429
Front Right Panel Removal And Installation…………430
Front Left Panel Removal And Installation………….430
GRILL……………………………………………..431
Removal And Installation…………………………431
GRILL FRAME………………………………………..433
Removal And Installation…………………………433
ENGINE SIDE COVERS………………………………….435
Removal And Installation…………………………435
FENDER…………………………………………….437
Removal And Installation…………………………437
ENGINE COVER……………………………………….439
Removal And Installation…………………………439
FUEL TANK………………………………………….441
Removal And Installation…………………………441
Screen Removal And Installation…………………..443
LIFT ARMS………………………………………….445
Removal And Installation…………………………445
BOB-TACH…………………………………………..449
Removal And Installation…………………………449
Bob-Tach Lever And Wedge…………………………451
Pivot Pin Bushing Removal And Installation…………452
ARM……………………………………………….453
Removal And Installation…………………………453
Arm Pivot Bushing Removal And Installation…………455
BOOM………………………………………………457
Removal And Installation…………………………457
SWING FRAME………………………………………..461
Removal And Installation…………………………461
Bushing Removal And Installation………………….462
X-CHANGE™………………………………………….463
Removal And Installation…………………………463
BUCKET…………………………………………….465
Backhoe Bucket Teeth Removal And Installation………465
Loader Bucket Teeth Removal And Installation……….465
BUCKET POSITIONING LINK……………………………..467
Removal And Installation…………………………467
CENTER FLOOR PANEL………………………………….469
Removal And Installation…………………………469
STABILIZER…………………………………………473
Removal And Installation…………………………473
ELECTRICAL SYSTEM AND ANALYSIS…………………………..475
ELECTRICAL SCHEMATIC………………………………..477
ELECTRICAL SYSTEM INFORMATION………………………..479
Troubleshooting Chart……………………………479
Description…………………………………….480
Fuse Location…………………………………..480
Relay Location………………………………….480
BATTERY……………………………………………481
Removal And Installation…………………………481
Servicing The Electrical System…………………..482
Using A Booster Battery (Jump Starting)……………483
ALTERNATOR…………………………………………485
Adjusting The Alternator Belt…………………….485
Description…………………………………….485
Tests………………………………………….486
Alternator Output Test…………………………..486
Full Field Test…………………………………487
Alternator Regulator Test………………………..487
Alternator Regulator Test With Voltmeter…………..488
Removal And Installation…………………………489
Parts Identification…………………………….490
Pulley Removal And Installation…………………..491
Disassembly And Assembly…………………………492
Rotor Continuity Test……………………………495
Stator Continuity Test…………………………..495
Rectifier Continuity (Diode) Test…………………496
Brush Length……………………………………496
STARTER……………………………………………497
Removal And Installation…………………………497
Checking The Starter In The Loader………………..497
Parts Identification…………………………….499
Disassembly…………………………………….500
Inspection And Repair……………………………505
No Load Test……………………………………509
Assembly……………………………………….510
FRONT LIGHTS……………………………………….517
Bulb Removal And Installation…………………….517
Housing Removal And Installation………………….519
TURN INDICATOR LIGHTS (FRONT)………………………..521
Bulb Removal And Installation…………………….521
TURN INDICATOR LIGHTS (REAR)…………………………523
Bulb Removal And Installation…………………….523
CAB LIGHTS…………………………………………525
Bulb Removal And Installation…………………….525
Housing Removal And Installation………………….527
FUEL LEVEL SENDER…………………………………..529
Removal And Installation…………………………529
INSTRUMENT PANEL……………………………………531
Removal And Installation…………………………531
ENGINE SERVICE…………………………………………533
TROUBLESHOOTING…………………………………….535
Chart………………………………………….535
ENGINE SPEED CONTROL………………………………..537
Removal And Installation…………………………537
Cable Removal And Installation……………………538
MUFFLER……………………………………………541
Removal And Installation…………………………541
AIR CLEANER………………………………………..543
Removal And Installation…………………………543
RADIATOR…………………………………………..545
Removal And Installation…………………………545
ENGINE COMPONENTS AND TESTING………………………..547
Valve Clearance Adjustment……………………….547
Engine Compression Checking………………………548
Fuel Shut-Off Solenoid Removal And Installation…….549
Checking Fuel Injection Pump……………………..550
Fuel Injection Pump Removal And Installation……….551
Fuel Injection Pump Timing……………………….553
Fuel Injector Nozzles……………………………554
Fuel Injector Nozzles Removal And Installation……..555
Fuel Injector Nozzles Check………………………556
ENGINE…………………………………………….557
Removal And Installation…………………………557
Mount Replacement……………………………….561
RECONDITIONING THE ENGINE……………………………563
Cylinder Head Removal And Installation…………….563
Cylinder Head Disassembly And Assembly…………….564
Cylinder Head Servicing………………………….565
Cylinder Head Top Clearance………………………565
Valve Guide Checking…………………………….566
Reconditioning The Valve And Valve Seat……………567
Valve Spring……………………………………568
Rocker Arm And Shaft Checking…………………….568
Timing Gearcase Cover Removal And Installation……..569
Idler Gear And Camshaft Removal And Installation……571
Camshaft Servicing………………………………572
Idler Gear And Shaft Servicing……………………573
Timing Gears Checking Backlash……………………574
Fuel Camshaft Removal And Installation…………….575
Fuel Camshaft Governor…………………………..575
Crankshaft Gear Removal And Installation…………..576
Oil Pump Removal And Installation…………………576
Oil Pump Service………………………………..576
Checking Engine Oil Pressure……………………..577
Oil Pump Relief Valve……………………………578
Piston And Connecting Rod Removal And Installation….578
Piston And Connecting Rod Servicing……………….580
Connecting Rod Alignment…………………………582
Crankshaft And Bearings Removal And Installation……582
Crankshaft And Bearings, Servicing………………..584
Cylinder Bore, Checking………………………….587
Water Pump Removal And Installation……………….588
Water Pump Disassembly And Assembly……………….588
FLYWHEEL HOUSING……………………………………589
Removal And Installation…………………………589
FLYWHEEL…………………………………………..591
Removal And Installation…………………………591
Ring Gear Removal And Installation………………..591
DRIVE COUPLER………………………………………593
Removal And Installation…………………………593
TURBOCHARGER……………………………………….595
SPECIFICATIONS…………………………………………597
LOADER SPECIFICATIONS……………………………….599
Loader Backhoe Dimensions………………………..599
Performance…………………………………….600
Controls……………………………………….600
Engine…………………………………………600
Electrical……………………………………..601
Drive System……………………………………601
Capacities……………………………………..601
Tires………………………………………….601
ENGINE SPECIFICATIONS……………………………….603
Fuel Injection Nozzles…………………………..603
Fuel Injection Pump……………………………..603
Cylinder Head…………………………………..603
Valves…………………………………………603
Valve Springs…………………………………..604
Valve Timing……………………………………604
Rocker Arms…………………………………….604
Camshaft……………………………………….604
Cylinders………………………………………604
Tappet…………………………………………604
Piston Rings……………………………………605
Pistons………………………………………..605
Crankshaft……………………………………..605
Oil Pump……………………………………….605
Thermostat……………………………………..606
Connecting Rods…………………………………606
Timing Gear…………………………………….606
Engine Bolt Torque………………………………607
Grinding Specifications for the Crankshaft…………608
LOADER BACKHOE TORQUE……………………………….609
Specifications………………………………….609
TORQUE SPECIFICATIONS FOR BOLTS………………………611
Torque For General Metric Bolts…………………..611
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS…………….613
Specifications………………………………….613
CONVERSIONS………………………………………..615
Decimal And Millimeter Equivalents………………..615
U.S. To Metric Conversion………………………..615
SMR…………………………………………………..617
B300-1…………………………………………….617
B300-2…………………………………………….619
B300-3…………………………………………….621
B300-4…………………………………………….623
B300-5…………………………………………….625
B300-6 ……………………………………………627

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DESCRIPTION:

BOBCAT B300 SN 571711001 Service Manual 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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