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Bobcat T190 Compact Track Loader Service Manual 6987043 (8-09) PDF Instant Download
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Bobcat T190 Compact Track Loader Service Manual 6987043 (8-09) – PDF DOWNLOAD
S/N 531660001 & Above
S/N 531760001 & Above
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Description
Bobcat T190 Compact Track Loader Service Manual 6987043 (8-09) – PDF DOWNLOAD
FILE DETAILS:
Bobcat T190 Compact Track Loader Service Manual 6987043 (8-09) – PDF DOWNLOAD
Language : English
Pages : 888
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T190 Compact Track Loader Service Manual 6987043 (8-09) – PDF DOWNLOAD
S/N 531660001 & Above
S/N 531760001 & 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 T190 Compact Track Loader Service Manual 6987043 (8-09) – PDF DOWNLOAD
MAINTENANCE SAFETY.............................................................................. 3 ALPHABETICAL INDEX.............................................................................. 5 CONTENTS........................................................................................ 7 FOREWORD.................................................................................... 8 SAFETY INSTRUCTIONS......................................................................... 11 FIRE PREVENTION............................................................................. 13 Maintenance............................................................................. 13 Operation............................................................................... 13 Electrical.............................................................................. 13 Hydraulic System........................................................................ 13 Fueling................................................................................. 13 Starting................................................................................ 13 Spark Arrestor Exhaust System........................................................... 13 Welding And Grinding.................................................................... 14 Fire Extinguishers...................................................................... 14 SERIAL NUMBER LOCATION...................................................................... 15 Loader Serial Number.................................................................... 15 Engine Serial Number.................................................................... 15 DELIVERY REPORT............................................................................. 16 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 - 6689779.............................................. 39 Description............................................................................. 39 Remote Start Tool (Service Tool) - 6689778.............................................. 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 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................................................... 57 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............................................... 62 Removing And Replacing Hydraulic Charge Filter.......................................... 63 Breather Cap............................................................................ 64 BOB-TACH (HAND LEVER)....................................................................... 65 Inspection And Maintenance.............................................................. 65 BOB-TACH (POWER)............................................................................ 67 Inspection And Maintenance.............................................................. 67 LUBRICATING THE LOADER...................................................................... 69 Lubrication Locations................................................................... 69 SPARK ARRESTOR MUFFLER...................................................................... 71 Cleaning Procedure...................................................................... 71 PIVOT PINS.................................................................................. 73 Inspection And Maintenance.............................................................. 73 LOADER STORAGE AND RETURN TO SERVICE........................................................ 75 Storage................................................................................. 75 Return To Service....................................................................... 75 STOPPING THE ENGINE AND LEAVING THE LOADER.................................................. 77 Procedure............................................................................... 77 Emergency Exit.......................................................................... 78 HYDRAULIC SYSTEM................................................................................ 79 HYDRAULIC / HYDROSTATIC SCHEMATICS.......................................................... 85 HYDRAULIC SYSTEM INFORMATION................................................................ 93 Glossary Of Hydraulic / Hydrostatic Symbols............................................. 93 Troubleshooting......................................................................... 97 CYLINDER (LIFT)............................................................................. 99 Testing................................................................................. 99 Removal And Installation................................................................100 Parts Identification....................................................................103 Disassembly And Assembly................................................................104 CYLINDER (TILT).............................................................................107 Testing.................................................................................107 Removal And Installation................................................................108 Rod End Pivot Pin Bushing And Seal Removal And Installation.............................110 Base End Pivot Pin Removal And Installation.............................................110 Parts Identification....................................................................111 Disassembly And Assembly................................................................112 CYLINDER (BOB-TACH).........................................................................115 Testing.................................................................................115 Removal And Installation................................................................116 Parts Identification....................................................................117 Disassembly And Assembly................................................................118 MAIN RELIEF VALVE...........................................................................121 Description.............................................................................121 Testing.................................................................................121 Adjusting...............................................................................123 Removal And Installation................................................................124 HYDRAULIC CONTROL VALVE (STANDARD)..........................................................125 Description.............................................................................125 Removal And Installation................................................................125 Identification Chart....................................................................130 Mount Bracket Removal And Installation..................................................131 Lift Load Check Valve Removal And Installation..........................................131 Load Check Valve Removal And Installation (Tilt & Auxiliary)............................132 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................133 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........134 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........134 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............135 Port Relief Valve Removal And Installation..............................................135 Plug Removal And Installation...........................................................136 Rubber Boot Removal And Installation....................................................137 End Cap / Spool Lock Block Removal And Installation.....................................138 Lift Spool And Detent Removal And Installation..........................................139 Tilt Spool Removal And Installation.....................................................149 Auxiliary Spool Removal And Installation................................................151 Auxiliary Solenoid Removal And Installation.............................................152 Solenoid Removal And Installation.......................................................153 Lock Valve Removal And Installation.....................................................155 Lift Arm Bypass Orifice Removal And Installation........................................157 Main Relief Valve Removal And Installation..............................................157 Check Valve Removal And Installation....................................................158 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)......................................................159 Description.............................................................................159 Removal And Installation................................................................159 Actuator Removal And Installation (Out of Loader).......................................164 Identification Chart....................................................................167 Mount Bracket Removal And Installation..................................................168 Lift Load Check Valve Removal And Installation..........................................168 Load Check Valve Removal And Installation (Tilt & Auxiliary)............................169 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................170 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........171 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........171 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............172 Port Relief Valve Removal And Installation..............................................172 Plug Removal And Installation...........................................................173 End Cap Block Removal And Installation..................................................174 Lift Spool And Detent Removal And Installation..........................................175 Tilt Spool Removal And Installation.....................................................180 Auxiliary Spool Removal And Installation................................................182 Auxiliary Solenoid Removal And Installation.............................................183 Solenoid Removal And Installation.......................................................184 Lock Valve Removal And Installation.....................................................186 Lift Arm Bypass Orifice Removal And Installation........................................188 Main Relief Valve Removal And Installation..............................................189 Check Valve Removal And Installation....................................................190 LIFT ARM BYPASS CONTROL VALVE...............................................................191 Description.............................................................................191 Testing.................................................................................191 Removal And Installation................................................................191 Disassembly And Assembly................................................................192 HYDRAULIC PUMP (STANDARD)...................................................................193 Description.............................................................................193 Pump Test At Quick Couplers.............................................................193 Direct Pump Test (Standard Section).....................................................194 Direct Pump Test (Charge Section).......................................................196 Removal And Installation................................................................198 Hydraulic Pump Startup..................................................................200 Parts Identification....................................................................201 Disassembly And Assembly................................................................202 HYDRAULIC PUMP (STANDARD) (HIGH FLOW).......................................................211 Description.............................................................................211 Pump Test At Quick Couplers.............................................................211 Direct Pump Test (Standard Section).....................................................212 Direct Pump Test (Charge Section).......................................................214 Direct Pump Test (High Flow Section)....................................................216 Removal And Installation................................................................218 Hydraulic Pump Startup..................................................................220 Parts Identification....................................................................221 Disassembly And Assembly................................................................222 HYDRAULIC PUMP (SJC)........................................................................235 Description.............................................................................235 Pump Test At Quick Couplers.............................................................235 Direct Pump Test (Standard Section).....................................................236 Direct Pump Test (Charge Section).......................................................238 Removal And Installation................................................................240 Hydraulic Pump Startup..................................................................242 Parts Identification....................................................................243 Disassembly And Assembly................................................................244 HYDRAULIC PUMP (SJC) (HIGH FLOW)............................................................253 Description.............................................................................253 Pump Test At Quick Couplers.............................................................253 Direct Pump Test (Standard Section).....................................................254 Direct Pump Test (Charge Section).......................................................256 Direct Pump Test (High Flow Section)....................................................258 Removal And Installation................................................................260 Hydraulic Pump Startup..................................................................262 Parts Identification....................................................................263 Disassembly And Assembly................................................................264 HYDRAULIC/HYDROSTATIC FILTERS...............................................................277 Description.............................................................................277 Housing Removal And Installation........................................................277 Charge Filter Housing Removal And Installation..........................................279 HYDRAULIC FLUID RESERVOIR...................................................................281 Description.............................................................................281 Removal And Installation................................................................281 Hydraulic Fluid Screen..................................................................283 OIL COOLER..................................................................................285 Description.............................................................................285 Removal And Installation................................................................285 BUCKET POSITION VALVE.......................................................................287 Description.............................................................................287 Solenoid Removal And Installation.......................................................287 Solenoid Testing........................................................................288 Removal And Installation................................................................289 Disassembly And Assembly................................................................290 REAR AUXILIARY DIVERTER VALVE...............................................................293 Description.............................................................................293 Solenoid Testing........................................................................293 Removal And Installation................................................................294 Disassembly And Assembly................................................................297 BOB-TACH (POWER) BLOCK......................................................................303 Description.............................................................................303 Removal And Installation................................................................303 Disassembly And Assembly................................................................305 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.....................................................309 Description.............................................................................309 Removal And Installation................................................................309 Disassembly And Assembly................................................................309 HIGH FLOW VALVE.............................................................................311 Description.............................................................................311 High Flow Relief Valve Testing..........................................................311 High Flow Relief Valve Adjustment.......................................................313 Solenoid Testing........................................................................314 Removal And Installation................................................................315 Disassembly And Assembly................................................................316 HYDROSTATIC SYSTEM..............................................................................319 HYDROSTATIC SYSTEM INFORMATION..............................................................321 Description.............................................................................321 Troubleshooting.........................................................................322 HYDROSTATIC MOTOR...........................................................................323 Description.............................................................................323 Removing And Replacing Oil..............................................................324 Removal And Installation................................................................326 Parts Identification....................................................................328 Disassembly And Assembly................................................................330 CHARGE PRESSURE.............................................................................341 Description.............................................................................341 Testing.................................................................................341 Sender Removal And Installation.........................................................343 Adjusting...............................................................................344 HYDROSTATIC PUMP............................................................................347 Description.............................................................................347 Replenishing / High Pressure Relief Valve Removal And Installation......................348 Removal And Installation................................................................349 Hydrostatic Pump Startup................................................................351 Parts Identification (Left Half)........................................................352 Parts Identification (Right Half).......................................................353 Disassembly.............................................................................354 Assembly................................................................................360 HYDROSTATIC PUMP (SJC)......................................................................367 Description.............................................................................367 Hydraulic Controller Removal And Installation...........................................368 Removal And Installation................................................................370 Hydrostatic Pump Startup................................................................372 Parts Identification....................................................................373 High Pressure Relief And Bypass Valve...................................................374 Charge Relief Valve.....................................................................375 Disassembly And Assembly................................................................376 Mechanical Neutral Adjustment...........................................................392 Hydraulic Controller Neutral Adjustment.................................................395 DRIVE BELT..................................................................................399 Description.............................................................................399 Shield Removal And Installation.........................................................399 Adjusting...............................................................................400 Belt Removal And Installation...........................................................401 Tensioner Pulley Removal And Installation...............................................402 Tensioner Pulley Parts Identification...................................................403 Tensioner Pulley Disassembly............................................................404 Tensioner Pulley Assembly...............................................................405 CASE DRAIN FILTER...........................................................................407 Description.............................................................................407 Disassembly And Assembly................................................................407 DRIVE SYSTEM....................................................................................409 BRAKE.......................................................................................411 Description.............................................................................411 Right Motor Brake Test..................................................................411 Left Motor Brake Test...................................................................412 Block Removal And Installation..........................................................413 Block Disassembly And Assembly..........................................................415 TRACK CARRIAGE COMPONENTS...................................................................417 Description.............................................................................417 Checking Tension........................................................................417 Adjusting Tension.......................................................................417 Track Removal And Installation..........................................................420 Idler (Front) Removal And Installation..................................................423 Idler (Rear) Removal And Installation...................................................425 Roller Removal And Installation.........................................................425 Sprocket Removal And Installation.......................................................426 Carriage Removal And Installation.......................................................427 Track Damage Identification.............................................................429 MAIN FRAME......................................................................................441 SEAT BAR....................................................................................445 Description.............................................................................445 Removal And Installation................................................................445 Disassembly And Assembly................................................................446 Compression Spring Disassembly And Assembly.............................................448 OPERATOR CAB................................................................................449 Gas Cylinder Removal And Installation...................................................449 Gas Cylinder Bracket Disassembly And Assembly...........................................451 Removal And Installation................................................................452 OPERATOR SEAT (SUSPENSION)..................................................................455 Removal And Installation................................................................455 Slide Rail Removal And Installation.....................................................456 Seat Belt Removal and Installation......................................................456 Lower Cushion Removal And Installation..................................................456 Back Cushion Removal And Installation...................................................458 Shock Removal And Installation..........................................................458 3-Point Seat Belt Removal And Installation..............................................459 BOB-TACH (HAND LEVER).......................................................................461 Description.............................................................................461 Removal And Installation................................................................461 Lever And Wedge Disassembly And Assembly................................................462 Pivot Pin Bushing And Seal Removal And Installation.....................................464 BOB-TACH (POWER)............................................................................465 Description.............................................................................465 Removal And Installation................................................................465 Lever And Wedge Disassembly And Assembly................................................467 Pivot Pin Bushing And Seal Removal And Installation.....................................468 LIFT ARMS...................................................................................469 Stabilizer Bar Removal And Installation.................................................469 Link Removal And Installation...........................................................470 Removal And Installation................................................................471 REAR GRILL..................................................................................475 Removal And Installation................................................................475 REAR DOOR...................................................................................477 Removal And Installation................................................................477 Striker Removal and Installation........................................................478 Striker Disassembly and Assembly........................................................478 Striker (Adjusting).....................................................................478 Latch Removal And Installation..........................................................479 FUEL TANK...................................................................................481 Removal And Installation................................................................481 Fuel Level Sender Removal And Installation..............................................482 Fuel Fill Screen Removal And Installation...............................................482 CONTROL PEDALS AND LINKAGES.................................................................483 Description.............................................................................483 Pedal Removal And Installation..........................................................483 Linkage Removal And Installation........................................................484 Pedal (Adjusting).......................................................................486 CONTROL PEDALS (ACS)........................................................................487 Description.............................................................................487 Foot Sensor Removal And Installation....................................................487 Foot Pedal Removal And Installation.....................................................488 Foot Pedal Linkage Disassembly And Assembly.............................................489 CONTROL PANEL...............................................................................491 Description.............................................................................491 Removal And Installation................................................................492 Shock Removal And Installation..........................................................495 Shaft Removal And Installation..........................................................495 Shaft Disassembly And Assembly..........................................................496 Linkage Removal And Installation........................................................497 Pintle Arm Disassembly And Assembly.....................................................501 Linkage Neutral (Adjusting).............................................................503 Linkage Travel (Adjusting)..............................................................507 CONTROL PANEL (SJC).........................................................................511 Description.............................................................................511 Removal And Installation................................................................511 CONTROL HANDLE / LEVER......................................................................513 Description.............................................................................513 Lever Removal And Installation..........................................................513 Boot Removal And Installation...........................................................514 CONTROL HANDLE / LEVER (ACS)................................................................515 Description.............................................................................515 Handle Sensor Removal And Installation..................................................515 Handle Removal And Installation.........................................................518 Handle Disassembly And Assembly.........................................................519 Lever Removal And Installation..........................................................519 Boot Removal And Installation...........................................................521 CONTROL HANDLE / LEVER (SJC)................................................................523 Description.............................................................................523 Joystick Testing........................................................................523 Joystick Removal And Installation.......................................................524 Joystick Mount Removal And Installation.................................................528 ACCESS PANEL (INSIDE).......................................................................531 Removal And Installation (Left).........................................................531 Removal And Installation (Right)........................................................531 ACCESS PANEL (INSIDE) (SJC).................................................................533 Removal And Installation (Left).........................................................533 Removal And Installation (Right)........................................................534 WINDOW (REAR)...............................................................................537 Removal.................................................................................537 Installation (Split Molding)............................................................537 Installation (Continuous Molding).......................................................539 WINDOW (TOP)................................................................................541 Removal And Installation................................................................541 WINDOW (SIDE)...............................................................................543 Removal And Installation................................................................543 WINDOW (CAB DOOR)...........................................................................545 Removal (Standard Window)...............................................................545 Installation (Standard Window)..........................................................546 Removal And Installation (Special Applications Window)..................................548 CAB DOOR....................................................................................549 Description.............................................................................549 Removal And Installation................................................................549 Aligning................................................................................550 Adjusting...............................................................................551 Checking Operation......................................................................551 ELECTRICAL SYSTEM & ANALYSIS....................................................................553 ELECTRICAL SCHEMATICS.......................................................................557 ELECTRICAL SYSTEM INFORMATION...............................................................563 Glossary Of Electrical Symbols..........................................................563 Standard Cab Harness Connectors.........................................................566 Deluxe Cab Harness Connectors...........................................................567 Mainframe Harness Connectors............................................................568 Description.............................................................................569 Troubleshooting.........................................................................570 Fuse And Relay Location / Identification................................................571 Solenoid Testing........................................................................572 BATTERY.....................................................................................573 Removal And Installation................................................................573 Servicing...............................................................................574 Using A Booster Battery (Jump Starting).................................................574 ALTERNATOR..................................................................................577 Belt Adjustment.........................................................................577 Belt Replacement........................................................................577 Charging System Inspection..............................................................578 Alternator Voltage Testing..............................................................579 Low Voltage Testing.....................................................................579 High Voltage Testing....................................................................580 Removal And Installation................................................................581 Parts Identification....................................................................582 STARTER.....................................................................................583 Testing.................................................................................583 Removal And Installation................................................................584 Parts Identification....................................................................585 INSTRUMENT PANELS...........................................................................587 Left Panel..............................................................................587 Standard Key Panel......................................................................589 Deluxe Instrumentation Panel............................................................590 Side Panel..............................................................................591 Front Panel.............................................................................591 Front Panel Removal And Installation....................................................592 Removal And Installation (Left And Right)...............................................593 Key Switch Removal And Installation.....................................................595 Alarm Removal And Installation..........................................................596 LIGHTS......................................................................................597 Front Removal And Installation..........................................................597 Rear Removal And Installation...........................................................598 Cab Light Removal And Installation......................................................598 BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)...................................................599 Description.............................................................................599 Connector Identification................................................................600 Removal and Installation................................................................606 BOBCAT CONTROLLER (ACS).....................................................................609 Description.............................................................................609 Connector And Wire Identification.......................................................610 Removal And Installation................................................................611 BOBCAT CONTROLLER (SJC) (DRIVE).............................................................613 Description.............................................................................613 Connector Identification................................................................614 Removal and Installation................................................................616 SPEED SENSOR (SJC)..........................................................................617 Description.............................................................................617 Testing.................................................................................617 Removal And Installation................................................................619 DIAGNOSTIC SERVICE CODES....................................................................623 Viewing Service Codes (Standard Key Panel)..............................................623 Viewing Service Codes (Deluxe Instrumentation Panel)....................................623 Service Codes List......................................................................624 BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......................................................629 Description.............................................................................629 Inspecting The BICS Controller (Engine STOPPED - Key ON)................................630 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....630 Inspecting The Seat Bar Sensor (Engine RUNNING).........................................630 Inspecting The Traction Lock (Engine RUNNING)...........................................630 Inspecting The Lift Arm Bypass Control..................................................630 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)........................630 Troubleshooting.........................................................................631 SEAT BAR SENSOR.............................................................................633 Description.............................................................................633 Troubleshooting.........................................................................633 Testing.................................................................................634 Removal And Installation................................................................635 Bobcat Interlock Control System (BICS) Circuit Test.....................................637 TRACTION LOCK...............................................................................639 Description.............................................................................639 Troubleshooting.........................................................................640 Inspecting..............................................................................641 CONTROL SYSTEM (ACS)........................................................................643 Description.............................................................................643 Troubleshooting.........................................................................644 Handle Sensor Connector Disassembly And Assembly........................................645 Switch Handle Removal...................................................................646 Switch Handle Installation..............................................................648 Actuator Connector Disassembly And Assembly.............................................651 Handle Lock Solenoid Removal And Installation...........................................652 Handle Lock Solenoid Disassembly And Assembly...........................................652 Foot Sensor Disassembly And Assembly....................................................653 Foot Lock Solenoid Removal And Installation.............................................654 ELECTRICAL / HYDRAULIC CONTROLS.............................................................655 Identification Chart....................................................................655 ELECTRICAL / HYDRAULIC CONTROLS (SJC).......................................................657 Identification Chart....................................................................657 SERVICE PC (LAPTOP COMPUTER)................................................................661 Connecting Remote Start Tool............................................................661 Connecting Remote Start Tool (Service Tool).............................................661 CALIBRATION.................................................................................663 Description.............................................................................663 Actuator Testing........................................................................663 Lift And Tilt Calibration (ACS).........................................................665 Lift And Tilt Calibration (SJC).........................................................667 Hydrostatic Pump Calibration (SJC)......................................................669 STEERING DRIFT COMPENSATION.................................................................675 Description.............................................................................675 Operation...............................................................................675 FLYWHEEL RPM SENSOR.........................................................................677 Description.............................................................................677 Adjusting...............................................................................677 CONTROL PANEL SETUP.........................................................................679 Right Panel Setup (Deluxe Instrumentation Panel)........................................679 Attachment Control Information (Deluxe Instrumentation Panel)...........................680 PASSWORD SETUP..............................................................................681 Password Description....................................................................681 Changing The Owner Password.............................................................681 Changing The User Passwords.............................................................682 Password Lockout Feature................................................................682 MAINTENANCE CLOCK...........................................................................683 Description.............................................................................683 Setup...................................................................................684 Reset...................................................................................687 BACK-UP ALARM SYSTEM........................................................................689 Description.............................................................................689 Inspecting..............................................................................689 Adjusting Switch Position...............................................................690 Troubleshooting (Standard And ACS)......................................................691 Troubleshooting (Joystick)..............................................................692 Alarm Removal And Installation..........................................................693 Switch Removal And Installation.........................................................693 ENGINE SERVICE..................................................................................695 ENGINE INFORMATION..........................................................................699 Description.............................................................................699 Engine Specifications...................................................................700 Engine Torque Values....................................................................704 Troubleshooting.........................................................................704 Removal And Installation................................................................706 Engine Mount Replacement................................................................713 Compression - Checking..................................................................714 ENGINE SPEED CONTROL........................................................................715 Removal And Installation................................................................715 ENGINE SPEED CONTROL (SJC)..................................................................717 Removal And Installation................................................................717 Disassembly And Assembly................................................................719 MUFFLER.....................................................................................721 Removal And Installation................................................................721 AIR CLEANER.................................................................................723 Housing Removal And Installation........................................................723 ENGINE COOLING SYSTEM.......................................................................725 Radiator Removal And Installation.......................................................725 Hydraulic Fan Description...............................................................728 Hydraulic Fan Disassembly And Assembly..................................................728 Blower Housing Removal And Installation.................................................729 Fan Removal And Installation............................................................731 Hydraulic Fan Motor Removal And Installation............................................731 Water Pump Removal And Installation.....................................................732 Water Pump Disassembly And Assembly.....................................................732 Thermostat Housing Removal And Installation.............................................733 Thermostat - Checking...................................................................734 LUBRICATION SYSTEM..........................................................................735 Oil Pan Removal And Installation........................................................735 Oil Pump Removal And Installation.......................................................735 Oil Pump Inspection.....................................................................736 Engine Oil Pressure - Testing...........................................................737 FUEL SYSTEM.................................................................................739 Fuel Shutoff Solenoid - Checking........................................................739 Fuel Shutoff Solenoid Removal And Installation..........................................739 Fuel Injection Pump - Checking..........................................................740 Fuel Injection Pump Removal And Installation............................................741 Governor Disassembly And Assembly.......................................................745 Fuel Camshaft Removal And Installation..................................................746 Fuel Injection Pump - Timing............................................................746 Fuel Injector Removal And Installation..................................................748 Fuel Injector Nozzle Pressure - Checking................................................750 Nozzle Spraying Condition...............................................................750 Valve Seat Tightness....................................................................751 CYLINDER HEAD...............................................................................753 Glow Plugs - Testing....................................................................753 Glow Plugs Removal And Installation.....................................................753 Valve Clearance Adjustment..............................................................754 Valve Timing, Checking..................................................................755 Cylinder Head Removal And Installation..................................................756 Cylinder Head Disassembly And Assembly..................................................759 Cylinder Head - Servicing...............................................................759 Cylinder Head Top Clearance.............................................................760 Valve Guide-Checking....................................................................760 Reconditioning The Valve And Valve Seat.................................................761 Valve Spring............................................................................763 Valve Tappets...........................................................................764 Rocker Arm And Shaft Checking...........................................................764 Push Rod Alignment - Checking...........................................................765 CRANKSHAFT AND PISTONS......................................................................767 Piston And Connecting Rod Removal And Installation......................................767 Piston And Connecting Rod - Servicing...................................................768 Cylinder Bore - Checking................................................................771 Connecting Rod Alignment................................................................771 Crankshaft Gear Removal And Installation................................................772 Crankshaft And Bearings Removal And Installation........................................772 Crankshaft And Bearings - Servicing.....................................................774 CAMSHAFT AND TIMING GEARS...................................................................779 Timing Gearcase Cover Removal And Installation..........................................779 Timing Gears Backlash-Checking..........................................................781 Idler Gear And Camshaft Removal And Installation........................................782 Camshaft - Servicing....................................................................783 Idler Gear And Shaft Servicing..........................................................784 TURBOCHARGER................................................................................785 Description.............................................................................785 Testing.................................................................................785 Removal And Installation................................................................786 FLYWHEEL AND HOUSING........................................................................789 Flywheel Removal And Installation.......................................................789 Ring Gear Removal And Installation......................................................789 Housing Removal And Installation........................................................790 HEATING, VENTILATION, AIR CONDITIONING..........................................................793 AIR CONDITIONING SYSTEM FLOW................................................................796 Description.............................................................................796 Chart...................................................................................797 Components..............................................................................798 Safety Equipment........................................................................801 REGULAR MAINTENANCE.........................................................................803 Filters.................................................................................803 Compressor Drive Belt Adjustment........................................................804 Compressor Drive Belt Replacement.......................................................804 Condenser...............................................................................804 Air Conditioning Lubrication............................................................804 Air Conditioning Service Chart..........................................................805 Evaporator / Heater Coil................................................................806 TROUBLESHOOTING.............................................................................807 Blower Motor Does Not Operate...........................................................807 Blower Motor Operates Normally, But Air Flow Is Insufficient............................807 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............807 The Compressor Does Not Operate At All, Or Operates Improperly..........................807 Gauge Pressure Related Troubleshooting..................................................808 Troubleshooting Tree....................................................................810 Temperature / Pressure Chart............................................................814 Poor A/C Performance....................................................................815 HVAC Repair And Leaks...................................................................816 Electrical System.......................................................................817 Engine Coolant Bypassing The Heater Valve...............................................825 Heater Valve Not Opening Or Closing.....................................................826 SYSTEM CHARGING AND RECLAMATION.............................................................827 Refrigerant Identification..............................................................827 Reclamation And Charging With Recovery / Charging Unit..................................828 Charging With A Manifold Gauge Set......................................................830 COMPRESSOR..................................................................................833 Removal And Installation................................................................833 Oil.....................................................................................834 Oil Check...............................................................................835 Clutch Disassembly And Assembly.........................................................837 CONDENSER...................................................................................841 Removal And Installation................................................................841 RECEIVER / DRIER............................................................................843 Receiver / Drier Removal And Installation...............................................843 Pressure Relief Valve Removal And Installation..........................................844 Pressure Switch Removal And Installation................................................845 Schraeder Valve Removal And Installation................................................846 EVAPORATOR / HEATER UNIT....................................................................847 Removal And Installation................................................................847 THERMOSTAT..................................................................................849 Removal And Installation................................................................849 EXPANSION VALVE.............................................................................851 Removal And Installation................................................................851 EVAPORATOR COIL.............................................................................853 Removal And Installation................................................................853 HEATER COIL.................................................................................855 Removal And Installation With A/C.......................................................855 Removal And Installation Without A/C....................................................857 BLOWER FAN..................................................................................859 Removal And Installation................................................................859 Disassembly And Assembly................................................................860 Connector Identification................................................................862 HEATER VALVE................................................................................863 Removal And Installation................................................................863 Disassembly And Assembly................................................................864 SPECIFICATIONS..................................................................................865 T190 LOADER SPECIFICATIONS..................................................................867 Dimensions..............................................................................867 Performance.............................................................................868 Controls................................................................................868 Engine..................................................................................868 Hydraulic System........................................................................869 Electrical..............................................................................869 Drive System............................................................................870 Capacities..............................................................................870 Tracks..................................................................................870 Ground Pressure.........................................................................870 TORQUE SPECIFICATIONS FOR BOLTS.............................................................871 Torque For General SAE Bolts............................................................871 Torque For General Metric Bolts.........................................................872 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................873 O-ring Face Seal Connection.............................................................873 Straight Thread O-ring Fitting..........................................................874 Tubelines And Hoses.....................................................................874 Flare Fitting...........................................................................875 Port Seal Fitting.......................................................................876 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................877 Specifications..........................................................................877 CONVERSIONS.................................................................................879 Decimal And Millimeter Equivalents......................................................879 U.S. To Metric Conversion Chart.........................................................879 SERVICE MANUAL REVISION.........................................................................881 Revision No: T190 - 1.......................................................................881 Revision No: T190 - 2.......................................................................883 Revision No: T190 - 3.......................................................................885 Revision No: T190 - 4.......................................................................887
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