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Bobcat T140 Compact Track Loader Service Manual 6987041 – PDF DOWNLOAD
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Bobcat T140 Compact Track Loader Service Manual 6987041 – PDF DOWNLOAD
S/N A3L720001 & Above
S/N A3L820001 & Above
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Description
Bobcat T140 Compact Track Loader Service Manual 6987041 – PDF DOWNLOAD
FILE DETAILS:
Bobcat T140 Compact Track Loader Service Manual 6987041 – PDF DOWNLOAD
Language : English
Pages : 801
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T140 Compact Track Loader Service Manual 6987041 – PDF DOWNLOAD
S/N A3L720001 & Above
S/N A3L820001 & 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.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS (Including side screens) is in good condition and is not modified.
2. Check that ROPS mounting hardware is tightened and is Bobcat approved.
3. The seat belt must be correctly installed, functional and in good condition.
4. The seat bar must be correctly adjusted, clean and lubricated.
5. Check lift arm support device, replace if damaged.
6. Machine signs (decals) must be legible and in the correct location.
7. Steering levers, hand controls and foot pedals must return to neutral (as applicable).
8. Check for correct function of the work lights.
9. The parking brake must function correctly.
10. Enclosure door latches must open and close freely.
11. Bob-Tach wedges and linkages must function correctly and be in good condition.
12. Safety treads must be in good condition.
13. Check for correct function of indicator lamps.
14. Check hydraulic fluid level, engine oil level and fuel supply.
15. Inspect for fuel, oil or hydraulic fluid leaks.
SAFETY INSTRUCTIONS:
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
• The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
• The AEM Safety Manual delivered with the machine gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Bobcat T140 Compact Track Loader Service Manual 6987041 – PDF DOWNLOAD
MAINTENANCE SAFETY................................................................................... 3 CONTENTS............................................................................................. 5 FOREWORD............................................................................................. 7 FOREWORD......................................................................................... 9 SAFETY INSTRUCTIONS.............................................................................. 11 FIRE PREVENTION.................................................................................. 13 Maintenance.................................................................................. 13 Operation.................................................................................... 13 Electrical................................................................................... 13 Hydraulic System............................................................................. 13 Fueling...................................................................................... 13 Starting..................................................................................... 13 Spark Arrester Exhaust System................................................................ 13 Welding And Grinding......................................................................... 14 Fire Extinguishers........................................................................... 14 SERIAL NUMBER LOCATIONS.......................................................................... 15 Loader Serial Number......................................................................... 15 Engine Serial Number......................................................................... 15 DELIVERY REPORT.................................................................................. 16 LOADER IDENTIFICATION............................................................................ 17 SAFETY & MAINTENANCE................................................................................. 19 LIFTING AND BLOCKING THE LOADER.................................................................. 21 Procedure.................................................................................... 21 LIFT ARM SUPPORT DEVICE.......................................................................... 23 Installing................................................................................... 23 Removing..................................................................................... 24 OPERATOR CAB..................................................................................... 25 Description.................................................................................. 25 Raising...................................................................................... 26 Lowering..................................................................................... 27 Cab Door Sensor.............................................................................. 28 Special Applications Kit..................................................................... 28 Special Applications Kit Inspection And Maintenance.......................................... 28 TRANSPORTING THE LOADER ON A TRAILER............................................................. 29 Loading And Unloading........................................................................ 29 Fastening.................................................................................... 29 TOWING THE LOADER................................................................................ 31 Procedure.................................................................................... 31 REMOTE START TOOL KIT-MEL1563.................................................................... 33 Remote Start Tool - MEL1563.................................................................. 33 Service Tool Harness Control - MEL1565....................................................... 34 Service Tool Harness Communicator - MEL1566.................................................. 35 Remote Start Procedure....................................................................... 36 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666................................................... 39 Description.................................................................................. 39 Remote Start Tool (Service Tool) - 7022042................................................... 40 Loader Service Tool Harness - 6689747........................................................ 41 Computer Service Tool Harness - 6689746...................................................... 42 Remote Start Procedure....................................................................... 43 SERVICE SCHEDULE................................................................................. 47 Chart........................................................................................ 47 AIR CLEANER SERVICE.............................................................................. 49 Replacing Filter Elements.................................................................... 49 ENGINE COOLING SYSTEM............................................................................ 51 Cleaning..................................................................................... 51 Checking Level............................................................................... 52 Removing And Replacing The Coolant........................................................... 52 FUEL SYSTEM...................................................................................... 53 Fuel Specifications.......................................................................... 53 Biodiesel Blend Fuel......................................................................... 53 Filling The Fuel Tank........................................................................ 54 Fuel Filter.................................................................................. 55 Removing Air From The Fuel System............................................................ 55 ENGINE LUBRICATION SYSTEM........................................................................ 57 Checking And Adding Engine Oil............................................................... 57 Engine Oil Chart............................................................................. 57 Removing And Replacing Oil And Filter........................................................ 58 HYDRAULIC / HYDROSTATIC SYSTEM................................................................... 59 Checking And Adding Fluid.................................................................... 59 Hydraulic / Hydrostatic Fluid Chart.......................................................... 59 Removing And Replacing Hydraulic Fluid....................................................... 60 Removing And Replacing Hydraulic / Hydrostatic Filter........................................ 61 Removing And Replacing Case Drain Filters.................................................... 61 Removing And Replacing Hydraulic Charge Filter............................................... 62 Breather Cap................................................................................. 62 BOB-TACH (HAND LEVER)............................................................................ 63 Inspection And Maintenance................................................................... 63 BOB-TACH (POWER)................................................................................. 65 Inspection And Maintenance................................................................... 65 LUBRICATING THE LOADER........................................................................... 67 Lubrication Locations........................................................................ 67 SPARK ARRESTER MUFFLER........................................................................... 69 Cleaning Procedure........................................................................... 69 PIVOT PINS....................................................................................... 71 Inspection And Maintenance................................................................... 71 LOADER STORAGE AND RETURN TO SERVICE............................................................. 73 Storage...................................................................................... 73 Return To Service............................................................................ 73 STOPPING THE ENGINE AND LEAVING THE LOADER....................................................... 75 Procedure.................................................................................... 75 EMERGENCY EXIT................................................................................... 77 Rear Window.................................................................................. 77 Front Door................................................................................... 77 SEAT BELT........................................................................................ 79 Inspection And Maintenance................................................................... 79 HYDRAULIC SYSTEM..................................................................................... 81 HYDRAULIC/HYDROSTATIC SCHEMATICS................................................................. 85 HYDRAULIC SYSTEM INFORMATION..................................................................... 89 Glossary Of Hydraulic / Hydrostatic Symbols.................................................. 89 Troubleshooting.............................................................................. 93 CYLINDER (LIFT).................................................................................. 95 Testing...................................................................................... 95 Removal And Installation..................................................................... 96 Parts Identification......................................................................... 97 Disassembly And Assembly..................................................................... 98 CYLINDER (TILT)..................................................................................101 Testing......................................................................................101 Removal And Installation.....................................................................101 Rod End Pivot Pin Bushing And Seal Removal And Installation..................................103 Base End Pivot Pin Removal And Installation..................................................103 Parts Identification.........................................................................104 Disassembly And Assembly.....................................................................105 CYLINDER (BOB-TACH)..............................................................................109 Testing......................................................................................109 Removal And Installation.....................................................................110 Parts Identification.........................................................................111 Disassembly And Assembly.....................................................................112 MAIN RELIEF VALVE................................................................................115 Description..................................................................................115 Testing......................................................................................116 Adjusting....................................................................................118 Removal And Installation.....................................................................119 HYDRAULIC CONTROL VALVE (STANDARD)...............................................................121 Description..................................................................................121 Removal And Installation.....................................................................122 Identification Chart.........................................................................126 Lift Load Check Valve Removal And Installation...............................................127 Load Check Valve Removal And Installation (Tilt And Auxiliary)...............................128 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)...............................129 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................130 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................130 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................131 Port Relief Valve Removal And Installation...................................................132 Plug Removal And Installation................................................................133 Rubber Boot Removal And Installation.........................................................134 End Cap / Spool Lock Block Removal And Installation..........................................134 Lift Spool And Detent Removal And Installation...............................................135 Tilt Spool Removal And Installation..........................................................145 Auxiliary Spool Removal And Installation.....................................................147 Auxiliary Solenoid Removal And Installation (S/N A3L734999 & Below And A3L834999 & Below)....149 Auxiliary Solenoid Removal And Installation (S/N A3L735001 & Above And A3L835001 & Above)....150 Solenoid Removal And Installation............................................................151 Lock Valve Removal And Installation..........................................................152 Lift Arm Bypass Orifice Removal And Installation.............................................154 Main Relief Valve Removal And Installation...................................................154 Check Valve Removal And Installation.........................................................155 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)...........................................................157 Description..................................................................................157 Removal And Installation.....................................................................158 Actuator Removal And Installation (Out Of Loader)............................................162 Identification Chart.........................................................................165 Lift Load Check Valve Removal And Installation...............................................166 Load Check Valve Removal And Installation (Tilt And Auxiliary)...............................167 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)...............................168 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................169 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................169 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................170 Port Relief Valve Removal And Installation...................................................170 Plug Removal And Installation................................................................171 End Cap Block Removal And Installation.......................................................172 Lift Spool And Detent Removal And Installation...............................................173 Tilt Spool Removal And Installation..........................................................178 Auxiliary Spool Removal And Installation.....................................................180 Auxiliary Solenoid Removal And Installation (S/N A3L734999 & Below And A3L834999 & Below)....182 Auxiliary Solenoid Removal And Installation (S/N A3L735001 & Above And A3L835001 & Above)....183 Solenoid Removal And Installation............................................................184 Lock Valve Removal And Installation..........................................................185 Lift Arm Bypass Orifice Removal And Installation.............................................187 Main Relief Valve Removal And Installation...................................................187 Check Valve Removal And Installation.........................................................188 LIFT ARM BYPASS CONTROL VALVE....................................................................189 Description..................................................................................189 Testing......................................................................................189 Removal And Installation.....................................................................189 Disassembly And Assembly.....................................................................190 HYDRAULIC PUMP (STANDARD)........................................................................191 Description..................................................................................191 Pump Test At Quick Couplers..................................................................191 Direct Pump Test (Standard Section)..........................................................192 Direct Pump Test (Charge Section)............................................................193 Removal And Installation.....................................................................197 Hydraulic Pump Startup.......................................................................199 Parts Identification.........................................................................200 Disassembly And Assembly.....................................................................201 HYDRAULIC PUMP (SJC).............................................................................209 Description..................................................................................209 Pump Test At Quick Couplers..................................................................209 Direct Pump Test (Standard Section)..........................................................210 Direct Pump Test (Charge Section)............................................................212 Removal And Installation.....................................................................214 Hydraulic Pump Startup.......................................................................214 Parts Identification.........................................................................215 Disassembly And Assembly.....................................................................216 HYDRAULIC / HYDROSTATIC FILTERS..................................................................217 Description..................................................................................217 Housing Removal And Installation.............................................................217 Charge Filter Housing Removal And Installation...............................................219 HYDRAULIC FLUID RESERVOIR........................................................................221 Description..................................................................................221 Removal And Installation.....................................................................221 Hydraulic Fluid Screen.......................................................................222 OIL COOLER.......................................................................................223 Description..................................................................................223 Removal And Installation.....................................................................223 BUCKET POSITION VALVE............................................................................225 Description..................................................................................225 Solenoid Removal And Installation............................................................225 Solenoid Testing.............................................................................226 Removal And Installation.....................................................................226 Disassembly And Assembly.....................................................................228 REAR AUXILIARY DIVERTER VALVE....................................................................231 Description..................................................................................231 Solenoid Testing.............................................................................231 Removal And Installation.....................................................................232 Disassembly And Assembly.....................................................................234 BOB-TACH (POWER) BLOCK...........................................................................241 Description..................................................................................241 Removal And Installation.....................................................................241 Disassembly And Assembly.....................................................................243 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK..........................................................247 Description..................................................................................247 Removal And Installation.....................................................................247 Disassembly And Assembly.....................................................................247 HYDROSTATIC SYSTEM...................................................................................249 HYDROSTATIC SYSTEM INFORMATION...................................................................251 Description..................................................................................251 Troubleshooting..............................................................................252 HYDROSTATIC DRIVE MOTOR (A3L735013 & BELOW, A3L835001 & BELOW)...................................253 Description..................................................................................253 Removing And Replacing Oil...................................................................254 Removal And Installation.....................................................................256 Parts Identification.........................................................................258 Disassembly And Assembly.....................................................................260 HYDROSTATIC DRIVE MOTOR (A3L735014 & ABOVE, A3L835002 & ABOVE)...................................271 Description..................................................................................271 Removing And Replacing Oil...................................................................272 Removal And Installation.....................................................................274 Parts Identification.........................................................................276 Disassembly And Assembly.....................................................................278 CHARGE PRESSURE..................................................................................289 Description..................................................................................289 Testing......................................................................................289 Sender Removal And Installation..............................................................290 Adjusting....................................................................................291 HYDROSTATIC PUMP.................................................................................293 Description..................................................................................293 Replenishing / High Pressure Relief Valve Removal And Installation...........................294 Removal And Installation.....................................................................295 Hydrostatic Pump Startup.....................................................................296 Parts Identification (Left Half).............................................................297 Parts Identification (Right Half)............................................................298 Disassembly..................................................................................299 Assembly.....................................................................................305 HYDROSTATIC PUMP (SJC)...........................................................................313 Description..................................................................................313 Hydraulic Controller Removal And Installation................................................314 Removal And Installation.....................................................................316 Hydrostatic Pump Startup.....................................................................317 Parts Identification.........................................................................318 High Pressure Relief And Bypass Valve........................................................319 Charge Relief Valve..........................................................................320 Disassembly And Assembly.....................................................................321 Mechanical Neutral Adjustment................................................................336 Hydraulic Controller Neutral Adjustment......................................................339 DRIVE BELT.......................................................................................343 Description..................................................................................343 Shield Removal And Installation..............................................................343 Adjusting....................................................................................344 Belt Removal And Installation................................................................346 Tensioner Pulley Removal And Installation....................................................347 Tensioner Pulley Parts Identification........................................................348 Tensioner Pulley Disassembly.................................................................349 Tensioner Pulley Assembly....................................................................350 CASE DRAIN FILTER................................................................................353 Description..................................................................................353 Disassembly And Assembly.....................................................................353 DRIVE SYSTEM.........................................................................................355 BRAKE............................................................................................357 Description..................................................................................357 Right Motor Brake Test.......................................................................357 Left Motor Brake Test........................................................................358 Block Removal And Installation...............................................................359 Block Disassembly And Assembly...............................................................361 TRACK UNDERCARRIAGE COMPONENTS...................................................................363 Description..................................................................................363 Checking Tension.............................................................................364 Adjusting Tension............................................................................365 Track Removal And Installation...............................................................367 Idler (Front) Removal And Installation.......................................................370 Track Tensioner Disassembly And Assembly (S/N A3L735017 & Below And A3L835001 & Below).......372 Track Tensioner Disassembly And Assembly (S/N A3L735018 & Above And A3L835002 & Above).......373 Idler (Rear) Removal And Installation........................................................374 Roller Removal And Installation..............................................................374 Sprocket Removal And Installation............................................................375 Track Housing Removal And Installation.......................................................376 TRACK MAINTENANCE................................................................................379 Track Damage Identification..................................................................379 MAINFRAME............................................................................................391 SEAT BAR.........................................................................................395 Description..................................................................................395 Removal And Installation.....................................................................395 Disassembly And Assembly.....................................................................396 Compression Spring Disassembly And Assembly..................................................397 OPERATOR CAB.....................................................................................399 Gas Cylinder Removal And Installation........................................................399 Gas Cylinder Bracket Disassembly And Assembly................................................401 Removal And Installation.....................................................................402 OPERATOR SEAT (SUSPENSION).......................................................................405 Removal And Installation.....................................................................405 Slide Rail Removal And Installation..........................................................406 Seat Belt Removal And Installation...........................................................406 Lower Cushion Removal And Installation.......................................................406 Back Cushion Removal And Installation........................................................408 Shock Removal And Installation...............................................................408 3-Point Seat Belt Removal And Installation...................................................409 BOB-TACH (HAND LEVER)............................................................................411 Description..................................................................................411 Removal And Installation.....................................................................411 Lever And Wedge Disassembly And Assembly.....................................................414 Bob-Tach Stops...............................................................................415 Pivot Pin Bushing And Seal Removal And Installation..........................................416 BOB-TACH (POWER).................................................................................417 Description..................................................................................417 Removal And Installation.....................................................................417 Lever And Wedge Disassembly And Assembly.....................................................419 Bob-Tach Stops...............................................................................420 Pivot Pin Bushing And Seal Removal And Installation..........................................421 LIFT ARMS........................................................................................423 Removal And Installation.....................................................................423 REAR GRILLE......................................................................................429 Removal And Installation.....................................................................429 REAR DOOR (TAILGATE).............................................................................431 Removal And Installation.....................................................................431 Striker Removal And Installation.............................................................432 Striker Disassembly And Assembly.............................................................432 Striker (Adjusting)..........................................................................433 Latch Removal And Installation...............................................................434 FUEL TANK........................................................................................435 Removal And Installation.....................................................................435 Fuel Level Sender Removal And Installation...................................................436 Fuel Fill Screen Removal And Installation....................................................436 CONTROL PEDALS AND LINKAGES......................................................................437 Description..................................................................................437 Pedal Removal And Installation...............................................................437 Linkage Removal And Installation.............................................................438 Pedal (Adjusting)............................................................................440 CONTROL PEDALS (ACS).............................................................................441 Description..................................................................................441 Foot Sensor Removal And Installation.........................................................441 Foot Pedal Removal And Installation..........................................................442 Foot Pedal Linkage Disassembly And Assembly..................................................443 CONTROL PANEL....................................................................................445 Description..................................................................................445 Removal And Installation.....................................................................446 Shock Removal And Installation...............................................................449 Shaft Removal And Installation...............................................................449 Shaft Disassembly And Assembly...............................................................450 Linkage Removal And Installation.............................................................451 Pintle Arm Disassembly And Assembly..........................................................455 Linkage Neutral (Adjusting)..................................................................457 Linkage Travel (Adjusting)...................................................................461 CONTROL PANEL (SJC)..............................................................................465 Description..................................................................................465 Removal And Installation.....................................................................465 CONTROL HANDLE / LEVER...........................................................................467 Description..................................................................................467 Lever Removal And Installation...............................................................467 Boot Removal And Installation................................................................467 CONTROL HANDLE / LEVER (ACS).....................................................................469 Description..................................................................................469 Handle Sensor Removal And Installation.......................................................469 Handle Removal And Installation..............................................................472 Handle Disassembly And Assembly..............................................................473 Lever Removal And Installation...............................................................473 Boot Removal And Installation................................................................475 CONTROL HANDLE / LEVER (SJC).....................................................................477 Description..................................................................................477 Joystick Testing.............................................................................477 Joystick Removal And Installation............................................................478 Joystick Mount Removal And Installation......................................................479 WINDOW (REAR)....................................................................................481 Removal......................................................................................481 Installation (Split Molding).................................................................481 Installation (Continuous Molding)............................................................483 WINDOW (TOP).....................................................................................485 Removal And Installation.....................................................................485 WINDOW (SIDE)....................................................................................487 Removal And Installation.....................................................................487 WINDOW (CAB DOOR)................................................................................489 Removal (Standard Window)....................................................................489 Installation (Standard Window)...............................................................490 Removal And Installation (Special Applications Window).......................................492 CAB DOOR.........................................................................................493 Description..................................................................................493 Removal And Installation.....................................................................493 Aligning.....................................................................................494 Adjusting....................................................................................495 Checking Operation...........................................................................495 ELECTRICAL SYSTEM & ANALYSIS.........................................................................497 ELECTRICAL SCHEMATICS............................................................................501 ELECTRICAL SYSTEM INFORMATION....................................................................508 Glossary Of Electrical Symbols...............................................................508 Standard Cab Harness Connectors..............................................................511 Deluxe Cab Harness Connectors................................................................512 Mainframe Harness Connectors.................................................................513 Description..................................................................................514 Troubleshooting..............................................................................515 Fuse And Relay Location / Identification.....................................................516 Solenoid Testing.............................................................................517 BATTERY..........................................................................................518 Removal And Installation.....................................................................518 Servicing....................................................................................519 Using A Booster Battery (Jump Starting)......................................................520 ALTERNATOR.......................................................................................522 Belt Adjustment..............................................................................522 Belt Replacement.............................................................................522 Charging System Inspection...................................................................523 Alternator Voltage Testing...................................................................524 Low Voltage Testing..........................................................................524 High Voltage Testing.........................................................................525 Removal And Installation.....................................................................526 Parts Identification.........................................................................527 STARTER..........................................................................................528 Testing......................................................................................528 Removal And Installation.....................................................................529 Parts Identification.........................................................................530 INSTRUMENT PANELS................................................................................532 Left Panel...................................................................................532 Standard Key Panel...........................................................................534 Keyless Start Panel..........................................................................534 Deluxe Instrumentation Panel.................................................................535 Side Panel...................................................................................536 Front Panel..................................................................................536 Front Panel Removal And Installation.........................................................537 Removal And Installation (Left And Right)....................................................537 Key Switch Removal And Installation..........................................................539 Alarm Removal And Installation...............................................................540 LIGHTS...........................................................................................542 Front Removal And Installation...............................................................542 Rear Removal And Installation................................................................543 Cab Light Removal And Installation...........................................................543 BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)........................................................544 Description..................................................................................544 Connector Identification.....................................................................545 Removal And Installation.....................................................................551 BOBCAT CONTROLLER (ACS)..........................................................................552 Description..................................................................................552 Connector And Wire Identification............................................................553 Removal And Installation.....................................................................554 BOBCAT CONTROLLER (SJC) (DRIVE)..................................................................556 Description..................................................................................556 Connector Identification.....................................................................557 Removal And Installation.....................................................................559 SPEED SENSORS (SJC)..............................................................................560 Description..................................................................................560 Testing......................................................................................560 Removal And Installation.....................................................................562 DIAGNOSTIC SERVICE CODES.........................................................................566 Viewing Service Codes........................................................................566 Service Codes List...........................................................................567 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..........................................................572 Description..................................................................................572 Inspecting The BICS™ (Engine STOPPED - Key ON)...............................................573 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON).........573 Inspecting The Seat Bar Sensor (Engine RUNNING)..............................................573 Inspecting The Traction Lock (Engine RUNNING)................................................573 Inspecting The Lift Arm Bypass Control.......................................................573 Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC).............................573 Troubleshooting..............................................................................574 SEAT BAR SENSOR..................................................................................576 Description..................................................................................576 Troubleshooting..............................................................................576 Testing......................................................................................577 Removal And Installation.....................................................................578 Bobcat Interlock Control System (BICS™) Circuit Test.........................................581 TRACTION LOCK....................................................................................584 Description..................................................................................584 Troubleshooting..............................................................................584 Inspecting...................................................................................585 Parking Brake Solenoid Removal And Installation..............................................586 CONTROL SYSTEM (ACS).............................................................................588 Description..................................................................................588 Troubleshooting..............................................................................589 Handle Sensor Connector Disassembly And Assembly.............................................590 Switch Handle Removal........................................................................591 Switch Handle Installation...................................................................593 Actuator Connector Disassembly And Assembly..................................................596 Handle Lock Solenoid Removal And Installation................................................597 Handle Lock Solenoid Disassembly And Assembly................................................597 Foot Sensor Disassembly And Assembly.........................................................598 Foot Lock Solenoid Removal And Installation..................................................599 ELECTRICAL / HYDRAULIC CONTROLS..................................................................600 Identification Chart.........................................................................600 Description..................................................................................601 Identification Chart ACD Group 0.............................................................602 Identification Chart ACD Group 1.............................................................603 Identification Chart ACD Group 2.............................................................604 Identification Chart ACD Group 3.............................................................605 ELECTRICAL / HYDRAULIC CONTROLS (ACS)............................................................606 Identification Chart.........................................................................606 Description..................................................................................607 Identification Chart ACD Group 0.............................................................608 Identification Chart ACD Group 1.............................................................609 Identification Chart ACD Group 2.............................................................610 Identification Chart ACD Group 3.............................................................611 ELECTRICAL / HYDRAULIC CONTROLS (SJC)............................................................612 Identification Chart.........................................................................612 Description..................................................................................613 Identification Chart ACD Group 0.............................................................614 Identification Chart ACD Group 1.............................................................615 Identification Chart ACD Group 2.............................................................616 Identification Chart ACD Group 3.............................................................617 SERVICE PC (LAPTOP COMPUTER).....................................................................618 Connecting Remote Start Tool.................................................................618 Connecting Remote Start Tool (Service Tool)..................................................618 CALIBRATION......................................................................................620 Description..................................................................................620 Actuator Testing.............................................................................620 Lift And Tilt Calibration (SJC)..............................................................623 Hydrostatic Pump Calibration (SJC)...........................................................625 Lift And Tilt Calibration (ACS)..............................................................630 STEERING DRIFT COMPENSATION......................................................................632 Description..................................................................................632 Operation....................................................................................632 FLYWHEEL RPM SENSOR..............................................................................634 Description..................................................................................634 Adjusting....................................................................................634 CONTROL PANEL SETUP..............................................................................636 Right Panel Setup (Deluxe Instrumentation Panel).............................................636 Attachment Control Information (Deluxe Instrumentation Panel)................................637 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....................................................638 Password Description.........................................................................638 Changing The Owner Password..................................................................638 Changing The User Passwords..................................................................639 Password Lockout Feature.....................................................................639 PASSWORD SETUP (KEYLESS START PANEL).............................................................640 Password Description.........................................................................640 Changing The Owner Password..................................................................640 Password Lockout Feature.....................................................................640 MAINTENANCE CLOCK................................................................................642 Description..................................................................................642 Setup........................................................................................643 Reset........................................................................................646 BACK-UP ALARM SYSTEM.............................................................................648 Description..................................................................................648 Inspecting...................................................................................648 Adjusting Switch Position....................................................................649 Troubleshooting (Standard And ACS)...........................................................650 Troubleshooting (Joystick)...................................................................651 Alarm Removal And Installation...............................................................652 Switch Removal And Installation..............................................................652 ENGINE SERVICE.......................................................................................654 ENGINE INFORMATION...............................................................................658 Description..................................................................................658 Specifications...............................................................................659 Torque Values................................................................................663 Troubleshooting..............................................................................664 Engine Removal And Installation..............................................................666 Engine Mount Replacement.....................................................................672 Compression - Checking.......................................................................673 ENGINE SPEED CONTROL.............................................................................674 Removal And Installation.....................................................................674 ENGINE SPEED CONTROL (SJC).......................................................................676 Removal And Installation.....................................................................676 Disassembly And Assembly.....................................................................678 MUFFLER..........................................................................................680 Removal And Installation.....................................................................680 AIR CLEANER......................................................................................682 Housing Removal And Installation.............................................................682 ENGINE COOLING SYSTEM............................................................................684 Radiator Removal And Installation............................................................684 Hydraulic Fan Description (S/N A3L729999 & Below, A3L82999 & Below)..........................686 Hydraulic Fan Disassembly And Assembly (S/N A3L729999 & Below, A3L82999 & Below).............686 Blower Housing Removal And Installation (S/N A3L729999 & Below, A3L82999 & Below)............687 Fan Removal And Installation (S/N A3L729999 & Below, A3L82999 & Below).......................689 Hydraulic Fan Motor Removal And Installation (S/N A3L729999 & Below, A3L82999 & Below).......689 Hydraulic Fan Description (S/N A3L730001 & Above, A3L830001 & Above).........................690 Hydraulic Fan Disassembly And Assembly (S/N A3L730001 & Above, A3L830001 & Above)............690 Blower Housing Removal And Installation (S/N A3L730001 & Above, A3L830001 & Above)...........691 Fan Removal And Installation (S/N A3L730001 & Above, A3L830001 & Above)......................693 Hydraulic Fan Motor Removal And Installation (S/N A3L730001 & Above, A3L830001 & Above)......693 Water Pump Removal And Installation..........................................................694 Water Pump Disassembly And Assembly..........................................................694 Thermostat Housing Removal And Installation..................................................695 Thermostat - Checking........................................................................696 LUBRICATION SYSTEM...............................................................................698 Oil Pan Removal And Installation.............................................................698 Oil Pump Removal And Installation............................................................698 Oil Pump Inspection..........................................................................699 Engine Oil Pressure - Testing................................................................700 FUEL SYSTEM......................................................................................702 Fuel Shutoff Solenoid - Checking.............................................................702 Fuel Shutoff Solenoid Removal And Installation...............................................702 Fuel Injection Pump - Checking...............................................................703 Fuel Injection Pump Removal And Installation.................................................704 Governor Disassembly And Assembly............................................................708 Fuel Camshaft Removal And Installation.......................................................709 Fuel Injection Pump - Timing.................................................................709 Fuel Injector Removal And Installation.......................................................711 Fuel Injector Nozzle Pressure - Checking.....................................................712 Nozzle Spray Condition.......................................................................713 Valve Seat Tightness.........................................................................713 CYLINDER HEAD....................................................................................714 Glow Plugs - Testing.........................................................................714 Glow Plugs Removal And Installation..........................................................714 Valve Clearance Adjustment...................................................................715 Valve Timing - Checking......................................................................716 Cylinder Head Removal And Installation.......................................................717 Cylinder Head Disassembly And Assembly.......................................................720 Cylinder Head - Servicing....................................................................720 Cylinder Head Top Clearance..................................................................721 Valve Guide - Checking.......................................................................721 Reconditioning The Valve And Valve Seat......................................................722 Valve Spring.................................................................................724 Valve Tappets................................................................................725 Rocker Arm And Shaft - Checking..............................................................725 Push Rod Alignment - Checking................................................................726 CRANKSHAFT AND PISTONS...........................................................................728 Piston And Connecting Rod Removal And Installation...........................................728 Piston And Connecting Rod - Servicing........................................................729 Cylinder Bore - Checking.....................................................................732 Connecting Rod Alignment.....................................................................732 Crankshaft Gear Removal And Installation.....................................................733 Crankshaft And Bearings Removal And Installation.............................................733 Crankshaft And Bearings - Servicing..........................................................735 CAMSHAFT AND TIMING GEARS........................................................................740 Timing Gearcase Cover Removal And Installation...............................................740 Timing Gears Backlash - Checking.............................................................742 Idler Gear And Camshaft Removal And Installation.............................................743 Camshaft - Servicing.........................................................................744 Idler Gear And Shaft Servicing...............................................................745 FLYWHEEL AND HOUSING.............................................................................746 Flywheel Removal And Installation............................................................746 Ring Gear Removal And Installation...........................................................746 Housing Removal And Installation.............................................................747 HEATING, VENTILATION, AIR CONDITIONING...............................................................750 HEATER SYSTEM....................................................................................752 Description..................................................................................752 REGULAR MAINTENANCE..............................................................................754 Filters......................................................................................754 Heater Coil..................................................................................754 TROUBLESHOOTING..................................................................................756 Blower Motor Does Not Operate................................................................756 Blower Motor Operators Normally, But Air Flow Is Insufficient................................756 Electrical System............................................................................757 Engine Coolant Bypassing The Heater Valve....................................................761 Heater Valve Not Opening Or Closing..........................................................762 HEATER UNIT......................................................................................764 Removal And Installation.....................................................................764 HEATER COIL......................................................................................766 Removal And Installation.....................................................................766 BLOWER FAN.......................................................................................768 Removal And Installation.....................................................................768 Disassembly And Assembly.....................................................................769 Connector Identification.....................................................................771 HEATER VALVE.....................................................................................772 Removal And Installation.....................................................................772 Disassembly And Assembly.....................................................................773 SPECIFICATIONS.......................................................................................774 (T140) LOADER SPECIFICATIONS.....................................................................776 Machine Dimensions...........................................................................776 Performance..................................................................................777 Engine.......................................................................................777 Controls.....................................................................................777 Drive System.................................................................................778 Hydraulic System.............................................................................778 Electrical...................................................................................779 Capacities...................................................................................779 Tracks.......................................................................................779 Ground Pressure..............................................................................779 TORQUE SPECIFICATIONS FOR BOLTS..................................................................780 Torque For General SAE Bolts.................................................................780 Torque For General Metric Bolts..............................................................781 HYDRAULIC CONNECTION SPECIFICATIONS..............................................................782 O-ring Face Seal Connection..................................................................782 Straight Thread O-ring Fitting...............................................................783 Tubelines And Hoses..........................................................................783 Flare Fitting................................................................................784 Port Seal Fitting............................................................................785 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS.....................................................786 Specifications...............................................................................786 CONVERSIONS......................................................................................788 Decimal And Millimeter Equivalent Chart......................................................788 U.S. To Metric Conversion Chart..............................................................788 SERVICE TOOLS REQUIRED...........................................................................790 Remote Start Tools...........................................................................790 Hydraulic Tools..............................................................................791 Mainframe And Drive Tools....................................................................793 Electrical Tools.............................................................................794 Engine Tools.................................................................................794 HVAC Tools...................................................................................799 ALPHABETICAL INDEX...................................................................................800
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V
