Bobcat L23 Small Articulated Loader Service Manual SN B4LC11001 & Above – PDF DOWNLOAD

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Bobcat L23 Small Articulated Loader Service Manual SN B4LC11001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat L23 Small Articulated Loader Service Manual SN B4LC11001 & Above – PDF DOWNLOAD

Language : English
Pages : 543
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Bobcat L23 Small Articulated Loader Service Manual SN B4LC11001 & Above – PDF DOWNLOAD

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 L23 Small Articulated Loader Service Manual SN B4LC11001 & Above – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
Call Before You Dig 12
Silica Dust Exposure 12
FIRE PREVENTION 12
Operation 12
Maintenance 12
Operation 12
Electrical 13
Hydraulic System 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 13
Fire Extinguishers 13
SERIAL NUMBER LOCATIONS 14
Machine Serial Number 14
Engine Serial Number 14
DELIVERY REPORT 15
Machine Front 16
Machine Rear 16
SAFETY AND MAINTENANCE 17
LIFTING AND BLOCKING THE SMALL ARTICULATED LOADER 19
Lifting And Blocking Procedure 19
LIFT ARM SUPPORT 21
Lift Arm Support Description 21
Installing Lift Arm Support 21
Removing Lift Arm Support 22
OPERATOR ENCLOSURE 23
Operator Enclosure Description 23
TRANSPORTING THE MACHINE 25
Loading And Unloading 25
Fastening 25
TOWING THE MACHINE 27
Towing Machine 27
REMOTE START TOOL (SERVICE TOOL) KIT – 7217666 29
Remote Start Tool Description 29
Remote Start Tool – 7022042 30
Service Tool Harness – 6689747 31
Computer Service Tool Harness – 6689746 32
SERVICE SCHEDULE 33
Maintenance Intervals 33
ENGINE AIR CLEANER 37
Replacing Engine Air Cleaner Filters 37
ENGINE COOLING SYSTEM 39
Cleaning Engine Cooling System 39
Checking And Adding Coolant 39
Replacing Coolant 41
FUEL SYSTEM 43
Fuel Specifications 43
Biodiesel Blend Fuel 43
Filling The Fuel Tank 44
Removing Water From Fuel Filter 45
Replacing Fuel Filter 46
Removing Air From The Fuel System 47
ENGINE LUBRICATION SYSTEM 49
Checking And Adding Engine Oil 49
Engine Oil Chart 49
Removing And Replacing Oil And Filter 50
HYDRAULIC / HYDROSTATIC SYSTEM 53
Checking And Adding Hydraulic Fluid 53
Hydraulic Fluid Chart 53
Replacing Hydraulic Fluid 54
Replacing Hydraulic / Hydrostatic Filter 57
BOB-TACH (HAND LEVER) 59
Inspecting And Maintaining Hand Lever Bob-Tach 59
BOB-TACH (POWER) 61
Inspecting And Maintaining Power Bob-Tach 61
MACHINE LUBRICATION 63
Lubricating Grease Fittings 63
Lubrication Locations 63
TIRE MAINTENANCE 65
Checking Wheel Nut Torque 65
Mounting Tires 65
MACHINE STOARGE AND RETURN TO SERVICE 67
Extended Storage Procedure 67
Returning The Machine To Service 67
STOPPING THE ENGINE AND LEAVING THE MACHINE 69
Stopping The Engine And Leaving The Machine 69
EMERGENCY EXIT 71
Performing An Emergency Exit 71
SEAT BELT 73
Inspecting And Maintaining The Seat Belt 73
SPARK ARRESTER 75
Cleaning Spark Arrester Muffler 75
HYDRAULIC SYSTEM 77
HYDRAULIC / HYDROSTATIC SCHEMATICS 81
HYDRAULIC SYSTEM INFORMATION 85
Glossary Of Hydraulic / Hydrostatic Symbols 85
Troubleshooting The Hydraulic System 89
Articulation Joint Hydraulic Hose Routing 90
LIFT CYLINDER 91
Testing Lift Cylinder 91
Removing And Installing Lift Cylinder 92
Parts Identification 94
Disassembling Lift Cylinder 96
Assembling Lift Cylinder 98
TILT CYLINDER 101
Testing Tilt Cylinder 101
Removing And Installing Tilt Cylinder 102
Parts Identification 104
Disassembling Tilt Cylinder 105
Assembling Tilt Cylinder 107
STEERING CYLINDER 111
Testing Steering Cylinder 111
Removing And Installing Steering Cylinder 112
Parts Identification 114
Disassembling Steering Cylinder 115
Assembling Steering Cylinder 117
MAIN RELIEF VALVE 121
Main Relief Valve Description 121
Testing Main Relief Valve 121
Removing And Installing Main Relief Valve 122
Adjusting Main Relive Valve 123
PORT RELIEF VALVE 125
Port Relief Valve Description 125
Testing Lift Port Relief Valve (Base End) 125
Testing Lift Port Relief Valve (Rod End) 126
Tilt Port Relief Valve Testing 127
HYDRAULIC CONTROL VALVE 129
Hydraulic Control Valve Description 129
Removing And Installing Hydraulic Control Valve 129
Identification Chart 133
Disassembling Hydraulic Control Valve 134
Disassembling And Assembling End Valve Section 136
Disassembling And Assembling End Valve Section 137
Disassembling And Assembling Lift Valve Section 138
Disassembling And Assembling Tilt Valve Section 143
Disassembling And Assembling Auxiliary Valve Section 147
Assembling Hydraulic Control Valve 152
PILOT MANIFOLD 155
Pilot Manifold Description 155
Removing And Installing Pilot Manifold 155
Parts Identification 157
Disassembling And Assembling Pilot Manifold 158
LIFT ARM CONTROL (BYPASS) 161
Lift Arm Control (Bypass) Description 161
Testing Lift Arm Control (Bypass) 162
IMPLEMENT PUMP 163
Implement Pump Description 163
Testing Lift, Tilt, and Auxiliary Sections 163
Removing And Installing Implement Pump 165
Parts Identification 166
Disassembling And Assembling Implement Pump 167
STEERING CONTROL UNIT 173
Steering Control Unit Description 173
Removing And Installing Steering Control Unit 173
Parts Identification 174
Disassembling And Assembling Steering Control Unit 175
HYDRAULIC / HYDROSTATIC FILTER 179
Hydraulic / Hydrostatic Filter Description 179
Removing And Installing Housing 179
JOYSTICK 181
Joystick Description 181
Removing And Installing Handle 181
HYDRAULIC FLUID RESERVOIR 183
Hydraulic Fluid Reservoir Description 183
Removing And Installing Hydraulic Reservoir 184
Removing And Installing Hydraulic Fluid Screen 186
OIL COOLER 187
Oil Cooler Description 187
Removing And Installing Oil Cooler 187
DRIVE PEDAL 189
Removing And Installing Drive Pedal 189
Disassembling And Assembling Drive Pedal 192
POWER BOB-TACH BLOCK 195
Power Bob-Tach Description 195
Removing And Installing Power Bob-Tach 195
Disassembling And Assembling Power Bob-Tach 197
AUXILIARY HYDRAULIC COUPLER BLOCK 203
Coupler Block Description 203
Removing And Installing Coupler Block 203
Disassembling And Assembling Coupler Block 204
TRACTION ASSIST 207
Traction Assist Description 207
Removing And Installing Traction Assist 207
Disassembling And Assembling Traction Assist 211
CASE DRAIN MANIFOLD 215
Case Drain Manifold Description 215
Removing And Installing Case Drain Manifold 215
HYDROSTATIC SYSTEM 217
HYDROSTATIC SYSTEM INFORMATION 219
Troubleshooting 219
Hydrostatic System Description 220
HYDROSTATIC MOTOR (SAPR BRAKE) 221
Hydrostatic Motor (SAPR Brake) Description 221
Removing And Installing Hydrostatic Motor (SAPR Brake) 221
Parts Identification 224
Disassembling Hydrostatic Motor (SAPR Brake) 225
Assembling Hydrostatic Motor (SAPR Brake) 232
HYDROSTATIC MOTOR 239
Hydrostatic Motor Description 239
Removing And Installing Hydrostatic Motor 239
Parts Identification 244
Disassembling Hydrostatic Motor 245
Assembling Hydrostatic Motor 250
HYDROSTATIC PUMP 255
Hydrostatic Pump Description 255
Removing And Installing Hydrostatic Pump 255
Parts Identification 258
Disassembling And Assembling Hydrostatic Pump 259
TURF TRACTION MANIFOLD 271
Turf Traction Manifold Description 271
Removing And Installing Turf Traction Manifold 271
Disassembling And Assembling Turf Traction Manifold 273
MAINFRAME 275
ENCLOSURE 277
Removing And Installing Enclosure 277
Removing And Installing Front Window 281
Removing And Installing Wiper Motor 282
Removing And Installing Rear Window 283
Removing And Installing Side Window 283
Removing And Installing Door 284
Removing And Installing Armrest 284
Removing And Installing Dash Cover 285
Removing And Installing Steering Wheel 286
Removing And Installing Operator Seat 286
Removing And Installing Floor Panel 287
BOB-TACH HAND LEVER 289
Bob-Tach Hand Lever Description 289
Removing And Installing Bob-Tach Hand Lever 289
Disassembling And Assembling Bob-Tach Hand Lever 290
Disassembling And Assembling Bob-Tach Hand Lever 291
BOB-TACH POWER 293
Removing And Installing Bob-Tach Power 293
Disassembling And Assembling Bob-Tach Power 295
PIVOT LINK 297
Removing And Installing Pivot Link 297
LIFT ARM 299
Removing And Installing Lift Arm 299
LEVELING LINK 301
Removing And Installing Leveling Link 301
REAR COVER 303
Removing And Installing Rear Cover 303
RIGHT REAR COVER 305
Removing And Installing Right Rear Cover 305
LEFT REAR COVER 307
Removing And Installing Left Rear Cover 307
CENTER COVER 309
Removing And Installing Center Cover 309
PUMP COVER 311
Removing And Installing Pump Cover 311
RIGHT FRONT COVER 313
Removing And Installing Right Front Cover 313
RIGHT CORNER COVER 315
Removing And Installing Right Corner Cover 315
LEFT FRONT COVER 317
Removing And Installing Left Front Cover 317
COUNTERWEIGHT 319
Removing And Installing Counterweight 319
FUEL TANK 321
Removing And Installing Fuel Tank 321
Removing And Installing Fuel Level Sender 322
ENCLOSURE BUMPERS 323
Removing And Installing Enclosure Bumpers 323
REAR GRILLE 325
Removing And Installing Rear Grille 325
ARTICULATION PIN 327
Removing And Installing Articulation Pin 327
ELECTRICAL SYSTEM AND ANALYSIS 329
ELECTRICAL SCHEMATICS 331
ELECTRICAL SYSTEM INFORMATION 344
Glossary Of Electrical Symbols 344
Electrical System Troubleshooting Chart 347
Electrical System Description 348
Fuse And Relay Location / Identification 349
BATTERY 352
Battery Maintenance 352
Maintaining Battery Charge Level 352
Battery Service During Machine Storage 352
Testing Battery 353
Charging Battery 353
Removing And Installing The Battery 354
Using A Booster Battery (Jump Starting) 355
ALTERNATOR 358
Adjusting Belt 358
Replacing Belt 358
Charging System Inspection 360
Testing Alternator Voltage 361
Removing And Installing Alternator 361
Parts Identification 363
STARTER 364
Testing Starter 364
Removing And Installing Starter 365
Parts Identification 366
INSTRUMENT PANEL 368
Removing And Installing Display Panel 368
LIGHTS 370
Removing And Installing Front lights 370
Removing And Installing Rear Light 370
GATEWAY CONTROLLER 372
Controller Description 372
Removing And Installing Gateway Controller 372
DIAGNOSTIC SERVICE CODES 376
Viewing Service Codes 376
Service Codes List 376
OPERATING INTERLOCK CONTROL SYSTEM 380
Operating Interlock Control System Description 380
Operating The Operator Interlock Control System 380
Inspecting The Operating Interlock Control System 381
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key On) 381
Inspecting The Armrest Sensor (Engine RUNNING) 381
Inspecting The Travel Pedal Interlocks (Engine RUNNING) 381
Inspecting The Lift Arm Bypass Control 382
ARMREST SENSOR 384
Armrest Sensor Description 384
Removing And Installing Armrest Sensor 384
SERVICE PC (LAPTOP COMPUTER) 386
Connecting The Remote Start Tool (Service Tool) 386
ELECTRIC COOLING FAN 388
Electric Cooling Fan Description 388
Removing And Installing Electric Cooling Fan 388
BACK-UP ALARM 390
Back-up Alarm Description 390
Inspecting Back-up Alarm 390
Troubleshooting Back-up Alarm 391
Removing And Installing Back-up Alarm 392
FRONT HORN 394
Removing And Installing Front Horn 394
Troubleshooting 395
FUEL LEVEL SENDER 396
Removing And Installing Fuel Level Sender 396
Testing Fuel Level Sender 397
KEY SWITCH 398
Removing And Installing Key Switch 398
BATTERY DISCONNECT SWITCH 400
Battery Disconnect Switch Description 400
Removing And Installing Battery Disconnect Switch 400
ENGINE SERVICE 402
ENGINE INFORMATION 404
Engine Description 404
Specifications 405
Crankshaft Re-Grind Data 411
Torque For Kubota® Metric Bolts 412
Troubleshooting 413
Removing And Installing Engine 414
Checking Compression 422
ENGINE SPEED CONTROL (LEVER) 424
Removing And Installing Engine Speed Control (Lever) 424
Calibrating Engine Speed Control 425
MUFFLER 426
Removing Muffler 426
Installing Muffler 427
EXHAUST PIPE 428
Removing And Installing Exhaust Pipe 428
AIR CLEANER 430
Removing And Installing Air Cleaner 430
ENGINE COOLING SYSTEM 432
Removing And Installing Coolant Recovery Tank 432
Removing And Installing Radiator 433
Removing And Installing Fan And Pulley 434
Removing And Installing Water Pump 435
Assembling And Disassembling Water Pump 435
Removing And Installing Thermostat Housing 436
Checking Thermostat 436
LUBRICATION SYSTEM 438
Removing And Installing Oil Pan 438
Removing And Installing Oil Pump 438
Inspecting Oil Pump 439
Testing Engine Oil Pressure 440
FUEL SYSTEM 442
Checking Fuel Shutoff Solenoid 442
Removing And Installing Fuel Shutoff Solenoid 443
Checking Fuel Injection Pump 444
Removing And Installing Fuel Injection Pump 445
Timing Fuel Injection Pump 449
Removing And Installing Fuel Camshaft 450
Fuel Camshaft Governor 451
Removing And Installing Fuel Injector 452
Checking Fuel Injector Nozzle Pressure 454
Checking Nozzle Spray Condition 455
Valve Seat Tightness 455
CYLINDER HEAD 456
Testing Glow Plugs 456
Removing And Installing Glow Plugs 456
Adjusting Valve Clearance 457
Checking Valve Timing 458
Removing And Installing Cylinder Head 459
Disassembling And Assembling Cylinder Head 464
Servicing Cylinder Head 464
Clearance Cylinder Head Top 465
Checking Valve Guide 465
Removing And Installing Valve Guide 466
Reconditioning The Valve And Valve Seat 467
Checking Valve Spring 468
Checking Valve Tappets 469
Checking Rocker Arm And Shaft 470
Checking Push Rod Alignment 470
CRANKSHAFT AND PISTONS 472
Removing And Installing Piston And Connecting Rod 472
Servicing Piston And Connecting Rod 474
Checking Cylinder Bore 476
Connecting Rod Alignment 477
Removing And Installing Crankshaft Gear 478
Removing And Installing Crankshaft And Bearings 479
Servicing Crankshaft And Bearings 482
CAMSHAFT AND TIMING GEARS 486
Removing And Installing Timing Gearcase Cover 486
Checking Timing Gears Backlash 488
Removing And Installing Idler Gear And Shaft 488
Servicing Camshaft 489
Servicing Idler Gear And Shaft 491
FLYWHEEL AND HOUSING 492
Removing And Installing Hydrostatic Pump Coupler 492
Removing And Installing Flywheel 494
Removing And Installing Flywheel Ring Gear 494
HEATING AND VENTILATION 496
REGULAR MAINTENANCE 498
Maintaining Fresh Air / Recirculation Filter 498
TROUBLESHOOTING 500
Blower Motor Does Not Operate 500
Blower Motor Operates Normally, But Air Flow Is Insufficient 500
Electrical System 501
HEATER UNIT 502
Removing And Installing Heater Unit 502
HEATER VALVE 504
Removing And Installing Heater Valve 504
HEATER COIL 506
Removal And Installation 506
BLOWER FAN 508
Removing And Installing Blower Fan 508
SPECIFICATIONS 510
SMALL ARTICULATED LOADER SPECIFICATIONS 512
Machine Dimensions 512
Performance Specifications 514
Controls Specifications 514
Engine Specifications 515
Hydraulic System Specifications 516
Electrical System Specifications 517
Drive System Specifications 517
Capacities Specifications 518
Tire Specifications 518
TECHNICAL SERVICE GUIDE SPECIFICATIONS 520
Engine 520
Engine Torques 520
Small Articulated Loader Torques 520
Cooling System 520
TORQUE SPECIFICATION FOR BOLTS 522
Torque For General SAE Bolts 522
Torque For General Metric Bolts 523
HYDRAULIC CONNECTION SPECIFICATIONS 524
O-ring Face Seal Connection 524
Straight Thread O-ring Fitting 524
Tubelines And Hoses 525
Flare Fitting 525
O-ring Flare Fitting 526
Port Seal Fitting 528
Push To Connect Fittings 529
HYDRAULIC FLUID SPECIFICATIONS 532
Specifications 532
CONVERSIONS 534
Decimal And Millimeter Equivalent Chart 534
U S To Metric Conversion Chart 535
SERVICE TOOLS REQUIRED 536
Remote Start Tools 536
Hydraulic Tools 537
Engine Tools 539
Electrical Tools 539
ALPHABETICAL INDEX 540

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