Description
Bobcat T190 Compact Track Loader Service Manual 6987052 – A3LN11001/A3LP11001 & Above
This extensive service manual is built around the Bobcat T190 Compact Track Loader and the serial-number groups S/N A3LN11001 & Above and S/N A3LP11001 & Above. It is a workshop-level reference for servicing, adjustment, troubleshooting, component removal and installation, testing, disassembly and assembly, and specification work across the loader’s major mechanical, hydraulic, hydrostatic, electrical, engine and HVAC systems. The foreword identifies the manual as a reference for the Bobcat loader mechanic, with detailed procedures for the loader and its component parts and systems.
File Details
- Manual type: Service Manual
- Brand / model: Bobcat T190 Compact Track Loader
- Serial coverage: S/N A3LN11001 & Above; S/N A3LP11001 & Above
- Language: English
- Page count: 888 PDF pages
- File format: PDF
- Manual number: 6987052 (8-08)
- Revision: T190-3
- Revision date: 14 August 2008
Serial-Number-Specific Service Coverage
The Bobcat T190 Compact Track Loader Service Manual 6987052 is specifically identified for loaders beginning at A3LN11001 and A3LP11001. The manual also explains why the loader serial number matters when requesting service information or ordering parts: early and later machines can use different parts or require different service procedures. The loader serial-number plate location and the engine serial-number location are illustrated near the front of the manual, helping technicians confirm the machine before beginning work.
Workshop Procedures, Testing and Diagnostics
This is not limited to routine maintenance. The procedures extend into system testing, pressure and flow checks, controller and sensor diagnosis, calibration, service-code interpretation, component overhaul and adjustment. Hydraulic sections include relief-valve testing and adjustment, cylinder testing and rebuilding, control-valve work, pump tests and hydraulic/hydrostatic schematics. Hydrostatic coverage follows the tandem pump and drive motors, charge pressure, drive belt and SJC pump procedures. Electrical chapters cover BICS, ACS and SJC controls, controllers, calibration, diagnostic service codes, sensors, starting and charging systems, instrumentation and electrical/hydraulic references.
The engine section covers the Kubota turbo diesel installation in depth, including engine information and specifications, compression checks, cooling, fuel injection, lubrication, cylinder head, crankshaft and pistons, camshaft and timing gears, EGR, flywheel and housing, muffler and turbocharger procedures. The loader specification pages identify the engine as Kubota V2607-DI-TE3B and provide rated output, idle speeds, torque, bore and stroke, capacities, hydraulic performance, machine dimensions, weights and other service data. Detailed torque values and service limits are also distributed throughout the individual procedures.
Diagrams and Component Identification
Illustrations are used throughout the Bobcat T190 service repair manual to show component locations, removal points, hose and tubeline routing, seal orientation, special-tool use and assembly order. The hydraulic/hydrostatic section includes complete schematics for standard, high-flow, SJC, and SJC with high-flow configurations for the stated serial-number ranges. Exploded component views and parts-identification drawings appear for assemblies such as hydraulic cylinders, pumps, valves and drive components, while electrical chapters provide connector, harness and control references for diagnosis.
Chapters Covered
- Safety & Maintenance
- Air cleaner, engine cooling, engine lubrication and fuel-system service
- Hydraulic/hydrostatic fluid, filter and breather-cap maintenance
- Lift-arm support, lifting/blocking, operator cab and pivot-pin procedures
- Bob-Tach hand-lever and Power Bob-Tach inspection and maintenance
- Service schedule, lubrication, storage/return to service and spark-arrestor muffler
- Remote Start Tool MEL1563 and Service Tool Kit 6689779 procedures
- Towing, trailer transport, stopping and emergency-exit procedures
- Hydraulic System
- Lift, tilt and Bob-Tach cylinder testing, removal, parts identification and overhaul
- Standard, ACS/SJC and high-flow hydraulic control-valve service
- Standard, high-flow and SJC hydraulic pump testing, removal and disassembly
- Main relief valve and lift-arm bypass control valve testing and adjustment
- Hydraulic reservoir, filters, oil cooler and front auxiliary coupler block
- Bucket-position valve, Power Bob-Tach block, high-flow valve and rear auxiliary diverter valve
- Hydraulic troubleshooting, symbol glossary and hydraulic/hydrostatic schematics
- Hydrostatic System
- Hydrostatic system description and troubleshooting
- Charge-pressure testing and adjustment
- Drive-belt service and tensioner procedures
- Hydrostatic motor removal, oil service, disassembly and assembly
- Hydrostatic pump removal, startup, parts identification, disassembly and assembly
- SJC hydrostatic pump controller, neutral-adjustment and relief-valve procedures
- Case-drain filter service
- Drive System
- Brake description, left/right motor brake tests and brake-block service
- Track-carriage inspection and adjustment
- Track removal and installation
- Rear idler, roller, sprocket and track-housing service
- Track-tensioner disassembly and assembly
- Main Frame
- Bob-Tach hand-lever and Power Bob-Tach assemblies
- Lift arms, operator cab, suspension seat and seat-bar components
- Standard, ACS and SJC control handles, control panels, pedals and linkages
- Fuel tank, rear door, rear grill and inside access panels
- Cab door adjustment and front, rear, side and top window service
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Bobcat T190 Compact Track Loader Service Manual 6987052 – A3LN11001/A3LP11001 & Above” are as follows:
MAINTENANCE SAFETYp. 3
ALPHABETICAL INDEXp. 5
Search (Ctrl+F)
+CONTENTSp. 7
FOREWORDp. 8
SAFETY INSTRUCTIONSp. 11
+FIRE PREVENTIONp. 13
Maintenancep. 13
Operationp. 13
Electricalp. 13
Hydraulic Systemp. 13
Fuelingp. 13
Startingp. 13
Spark Arrestor Exhaust Systemp. 13
Welding And Grindingp. 14
Fire Extinguishersp. 14
+SERIAL NUMBER LOCATIONp. 15
Loader Serial Numberp. 15
Engine Serial Numberp. 15
DELIVERY REPORTp. 16
LOADER IDENTIFICATIONp. 17
+SAFETY & MAINTENANCEp. 19
+LIFTING AND BLOCKING THE LOADERp. 21
+LIFT ARM SUPPORT DEVICEp. 23
Installingp. 23
Removingp. 24
+OPERATOR CABp. 25
Descriptionp. 25
Raisingp. 26
Loweringp. 27
Cab Door Sensorp. 28
Special Applications Kitp. 28
Special Applications Kit Inspection And Maintenancep. 28
+TRANSPORTING THE LOADER ON A TRAILERp. 29
Loading And Unloadingp. 29
Fasteningp. 29
+TOWING THE LOADERp. 31
+REMOTE START TOOL KIT-MEL1563p. 33
Remote Start Tool – MEL1563p. 33
Service Tool Harness Control – MEL1565p. 34
Service Tool Harness Communicator – MEL1566p. 35
Remote Start Procedurep. 36
+REMOTE START TOOL (SERVICE TOOL) KIT – 6689779p. 39
Descriptionp. 39
Remote Start Tool (Service Tool) – 6689778p. 40
Loader Service Tool Harness – 6689747p. 41
Computer Service Tool Harness – 6689746p. 42
Remote Start Procedurep. 43
+SERVICE SCHEDULEp. 47
+AIR CLEANER SERVICEp. 49
Replacing Filter Elementsp. 49
+ENGINE COOLING SYSTEMp. 51
Cleaningp. 51
Checking Levelp. 52
Removing And Replacing Coolantp. 52
+FUEL SYSTEMp. 53
Fuel Specificationsp. 53
Biodiesel Blend Fuelp. 53
Filling The Fuel Tankp. 54
Fuel Filterp. 55
Removing Air From The Fuel Systemp. 55
+ENGINE LUBRICATION SYSTEMp. 57
Checking And Adding Engine Oilp. 57
Engine Oil Chartp. 57
Removing And Replacing Oil And Filterp. 57
+HYDRAULIC / HYDROSTATIC SYSTEMp. 59
Checking And Adding Fluidp. 59
Hydraulic / Hydrostatic Fluid Chartp. 59
Removing And Replacing Hydraulic Fluidp. 60
Removing And Replacing Hydraulic / Hydrostatic Filterp. 61
Removing And Replacing Case Drain Filtersp. 62
Removing And Replacing Hydraulic Charge Filterp. 63
Breather Capp. 64
+BOB-TACH (HAND LEVER)p. 65
Inspection And Maintenancep. 65
+BOB-TACH (POWER )p. 67
Inspection And Maintenancep. 67
+LUBRICATING THE LOADERp. 69
Lubrication Locationsp. 69
+SPARK ARRESTOR MUFFLERp. 71
+PIVOT PINSp. 73
Inspection And Maintenancep. 73
+LOADER STORAGE AND RETURN TO SERVICEp. 75
Storagep. 75
Return To Servicep. 75
+STOPPING THE ENGINE AND LEAVING THE LOADERp. 77
Procedurep. 77
Emergency Exitp. 78
+HYDRAULIC SYSTEMp. 79
HYDRAULIC/HYDROSTATIC SCHEMATICSp. 85
+HYDRAULIC SYSTEM INFORMATIONp. 93
Glossary Of Hydraulic / Hydrostatic Symbolsp. 93
Troubleshootingp. 97
+CYLINDER (LIFT)p. 99
Testingp. 99
Removal And Installationp. 100
Parts Identificationp. 103
Disassembly And Assemblyp. 104
+CYLINDER (TILT)p. 107
Testingp. 107
Removal And Installationp. 108
Rod End Pivot Pin Bushing And Seal Removal And Installationp. 110
Base End Pivot Pin Removal And Installationp. 110
Parts Identificationp. 111
Disassembly And Assemblyp. 112
+CYLINDER (BOB-TACH)p. 115
Testingp. 115
Removal And Installationp. 116
Parts Identificationp. 117
Disassembly And Assemblyp. 118
+MAIN RELIEF VALVEp. 121
Descriptionp. 121
Testingp. 121
Adjustingp. 123
Removal And Installationp. 124
+HYDRAULIC CONTROL VALVE (STANDARD)p. 125
Descriptionp. 125
Removal And Installationp. 125
Identification Chartp. 130
Mount Bracket Removal And Installationp. 131
Lift Load Check Valve Removal And Installationp. 131
Load Check Valve Removal And Installation (Tilt & Auxiliary)p. 132
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)p. 133
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)p. 134
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)p. 134
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)p. 135
Port Relief Valve Removal And Installationp. 135
Plug Removal And Installationp. 136
Rubber Boot Removal And Installationp. 137
End Cap / Spool Lock Block Removal And Installationp. 138
Lift Spool And Detent Removal And Installationp. 139
Tilt Spool Removal And Installationp. 149
Auxiliary Spool Removal And Installationp. 151
Auxiliary Solenoid Removal And Installationp. 152
Solenoid Removal And Installationp. 153
Lock Valve Removal And Installationp. 155
Lift Arm Bypass Orifice Removal And Installationp. 157
Main Relief Valve Removal And Installationp. 157
Check Valve Removal And Installationp. 158
+HYDRAULIC CONTROL VALVE (ACS) OR (SJC)p. 159
Descriptionp. 159
Removal And Installationp. 159
Actuator Removal And Installation (Out of Loader)p. 164
Identification Chartp. 167
Mount Bracket Removal And Installationp. 168
Lift Load Check Valve Removal And Installationp. 168
Load Check Valve Removal And Installation (Tilt & Auxiliary)p. 169
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)p. 170
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)p. 171
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)p. 171
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)p. 172
Port Relief Valve Removal And Installationp. 172
Plug Removal And Installationp. 173
End Cap Block Removal And Installationp. 174
Lift Spool And Detent Removal And Installationp. 175
Tilt Spool Removal And Installationp. 180
Auxiliary Spool Removal And Installationp. 182
Auxiliary Solenoid Removal And Installationp. 183
Solenoid Removal And Installationp. 184
Lock Valve Removal And Installationp. 186
Lift Arm Bypass Orifice Removal And Installationp. 188
Main Relief Valve Removal And Installationp. 189
Check Valve Removal And Installationp. 190
+LIFT ARM BYPASS CONTROL VALVEp. 191
Descriptionp. 191
Testingp. 191
Removal And Installationp. 191
Disassembly And Assemblyp. 192
+HYDRAULIC PUMP (STANDARD)p. 193
Descriptionp. 193
Pump Test At Quick Couplersp. 193
Direct Pump Test (Standard Section)p. 194
Direct Pump Test (Charge Section)p. 196
Removal And Installationp. 198
Hydraulic Pump Startupp. 200
Parts Identificationp. 201
Disassembly And Assemblyp. 202
+HYDRAULIC PUMP (STANDARD) (HIGH FLOW)p. 211
Descriptionp. 211
Pump Test At Quick Couplersp. 211
Direct Pump Test (Standard Section)p. 212
Direct Pump Test (Charge Section)p. 214
Direct Pump Test (High Flow Section)p. 216
Removal And Installationp. 218
Hydraulic Pump Startupp. 220
Parts Identificationp. 221
Disassembly And Assemblyp. 222
+HYDRAULIC PUMP (SJC)p. 235
Descriptionp. 235
Pump Test At Quick Couplersp. 235
Direct Pump Test (Standard Section)p. 236
Direct Pump Test (Charge Section)p. 238
Removal And Installationp. 240
Hydraulic Pump Startupp. 242
Parts Identificationp. 243
Disassembly And Assemblyp. 244
+HYDRAULIC PUMP (SJC) (HIGH FLOW)p. 253
Descriptionp. 253
Pump Test At Quick Couplersp. 253
Direct Pump Test (Standard Section)p. 254
Direct Pump Test (Charge Section)p. 256
Direct Pump Test (High Flow Section)p. 258
Removal And Installationp. 260
Hydraulic Pump Startupp. 262
Parts Identificationp. 263
Disassembly And Assemblyp. 264
+HYDRAULIC/HYDROSTATIC FILTERSp. 277
Descriptionp. 277
Housing Removal And Installationp. 277
Charge Filter Housing Removal And Installationp. 279
+HYDRAULIC FLUID RESERVOIRp. 281
Descriptionp. 281
Removal And Installationp. 281
Hydraulic Fluid Screenp. 283
+OIL COOLERp. 285
Descriptionp. 285
Removal And Installationp. 285
+BUCKET POSITION VALVEp. 287
Descriptionp. 287
Solenoid Removal And Installationp. 287
Solenoid Testingp. 288
Removal And Installationp. 289
Disassembly And Assemblyp. 290
+REAR AUXILIARY DIVERTER VALVEp. 293
Descriptionp. 293
Solenoid Testingp. 293
Removal And Installationp. 294
Disassembly And Assemblyp. 297
+BOB-TACH (POWER) BLOCKp. 303
Descriptionp. 303
Removal And Installationp. 303
Disassembly And Assemblyp. 305
+FRONT AUXILIARY HYDRAULIC COUPLER BLOCKp. 309
Descriptionp. 309
Removal And Installationp. 309
Disassembly And Assemblyp. 309
+HIGH FLOW VALVEp. 311
Descriptionp. 311
High Flow Relief Valve Testingp. 311
High Flow Relief Valve Adjustmentp. 313
Solenoid Testingp. 314
Removal And Installationp. 315
Disassembly And Assemblyp. 316
+HYDROSTATIC SYSTEMp. 319
+HYDROSTATIC SYSTEM INFORMATIONp. 321
Descriptionp. 321
Troubleshootingp. 322
+HYDROSTATIC MOTORp. 323
Descriptionp. 323
Removing And Replacing Oilp. 324
Removal And Installationp. 326
Parts Identificationp. 328
Disassembly And Assemblyp. 330
+CHARGE PRESSUREp. 341
Descriptionp. 341
Testingp. 341
Sender Removal And Installationp. 343
Adjustingp. 344
+HYDROSTATIC PUMPp. 347
Descriptionp. 347
Replenishing / High Pressure Relief Valve Removal And Installationp. 348
Removal And Installationp. 349
Hydrostatic Pump Startupp. 351
Parts Identification (Left Half)p. 352
Parts Identification (Right Half)p. 353
Disassemblyp. 354
Assemblyp. 360
+HYDROSTATIC PUMP (SJC)p. 367
Descriptionp. 367
Hydraulic Controller Removal And Installationp. 368
Removal And Installationp. 370
Hydrostatic Pump Startupp. 372
Parts Identificationp. 373
High Pressure Relief And Bypass Valvep. 374
Charge Relief Valvep. 375
Disassembly And Assemblyp. 376
Mechanical Neutral Adjustmentp. 392
Hydraulic Controller Neutral Adjustmentp. 395
+DRIVE BELTp. 399
Descriptionp. 399
Shield Removal And Installationp. 399
Adjustingp. 400
Belt Removal And Installationp. 401
Tensioner Pulley Removal And Installationp. 402
Tensioner Pulley Parts Identificationp. 403
Tensioner Pulley Disassemblyp. 404
Tensioner Pulley Assemblyp. 405
+CASE DRAIN FILTERp. 407
Descriptionp. 407
Disassembly And Assemblyp. 407
+DRIVE SYSTEMp. 409
+BRAKEp. 411
Descriptionp. 411
Right Motor Brake Testp. 411
Left Motor Brake Testp. 412
Block Removal And Installationp. 413
Block Disassembly And Assemblyp. 415
+TRACK CARRIAGE COMPONENTSp. 417
Descriptionp. 417
Checkingp. 418
Adjustingp. 418
Track Removal And Installationp. 420
Track Tensioner Disassembly And Assemblyp. 425
Idler (Rear) Removal And Installationp. 426
Roller Removal And Installationp. 426
Sprocket Removal And Installationp. 427
Track Housing Removal And Installationp. 428
+MAIN FRAMEp. 431
+SEAT BARp. 435
Descriptionp. 435
Removal And Installationp. 435
Disassembly And Assemblyp. 436
Compression Spring Disassembly And Assemblyp. 437
+OPERATOR CABp. 439
Gas Cylinder Removal And Installationp. 439
Gas Cylinder Bracket Disassembly And Assemblyp. 441
Removal And Installationp. 442
+OPERATOR SEAT (SUSPENSION)p. 445
Removal And Installationp. 445
Slide Rail Removal And Installationp. 446
Seat Belt Removal and Installationp. 446
Lower Cushion Removal And Installationp. 446
Back Cushion Removal And Installationp. 448
Shock Removal And Installationp. 448
3-Point Seat Belt Removal And Installationp. 449
+BOB-TACH (HAND LEVER)p. 451
Descriptionp. 451
Removal And Installationp. 451
Lever And Wedge Disassembly And Assemblyp. 452
Pivot Pin Bushing And Seal Removal And Installationp. 454
+BOB-TACH (POWER)p. 455
Descriptionp. 455
Removal And Installationp. 455
Lever And Wedge Disassembly And Assemblyp. 457
Pivot Pin Bushing And Seal Removal And Installationp. 458
+LIFT ARMSp. 459
Stabilizer Bar Removal And Installationp. 459
Link Removal And Installationp. 460
Removal And Installationp. 461
+REAR GRILLp. 465
Removal And Installationp. 465
+REAR DOORp. 467
Removal And Installationp. 467
Striker Removal and Installationp. 468
Striker Disassembly and Assemblyp. 468
Striker (Adjusting)p. 468
Latch Removal And Installationp. 469
+FUEL TANKp. 471
Removal And Installationp. 471
Fuel Level Sender Removal And Installationp. 472
Fuel Fill Screen Removal And Installationp. 472
+CONTROL PEDALS AND LINKAGESp. 473
Descriptionp. 473
Pedal Removal And Installationp. 473
Linkage Removal And Installationp. 474
Pedal (Adjusting)p. 476
+CONTROL PEDALS (ACS)p. 477
Descriptionp. 477
Foot Sensor Removal And Installationp. 477
Foot Pedal Removal And Installationp. 478
Foot Pedal Linkage Disassembly And Assemblyp. 479
+CONTROL PANELp. 481
Descriptionp. 481
Removal And Installationp. 482
Shock Removal And Installationp. 485
Shaft Removal And Installationp. 485
Shaft Disassembly And Assemblyp. 486
Linkage Removal And Installationp. 487
Pintle Arm Disassembly And Assemblyp. 491
Linkage Neutral (Adjusting)p. 493
Linkage Travel (Adjusting)p. 497
+CONTROL PANEL (SJC)p. 501
Descriptionp. 501
Removal And Installationp. 501
+CONTROL HANDLE / LEVERp. 503
Descriptionp. 503
Lever Removal And Installationp. 503
Boot Removal And Installationp. 504
+CONTROL HANDLE / LEVER (ACS)p. 505
Descriptionp. 505
Handle Sensor Removal And Installationp. 505
Handle Removal And Installationp. 508
Handle Disassembly And Assemblyp. 509
Lever Removal And Installationp. 509
Boot Removal And Installationp. 511
+CONTROL HANDLE / LEVER (SJC)p. 513
Descriptionp. 513
Joystick Testingp. 513
Joystick Removal And Installationp. 514
Joystick Mount Removal And Installationp. 518
+ACCESS PANEL (INSIDE)p. 521
Removal And Installation (Left)p. 521
Removal And Installation (Right)p. 521
+ACCESS PANEL (INSIDE) (SJC)p. 523
Removal And Installation (Left)p. 523
Removal And Installation (Right)p. 524
+WINDOW (REAR)p. 527
Removalp. 527
Installationp. 527
+WINDOW (TOP)p. 529
Removal And Installationp. 529
+WINDOW (SIDE)p. 531
Removal And Installationp. 531
+WINDOW (CAB DOOR)p. 533
Removal (Standard Window)p. 533
Installation (Standard Window)p. 534
Removal And Installation (Special Applications Window)p. 536
+CAB DOORp. 537
Descriptionp. 537
Removal And Installationp. 537
Aligningp. 538
Adjustingp. 539
Checking Operationp. 539
+ELECTRICAL SYSTEM & ANALYSISp. 541
ELECTRICAL SCHEMATICSp. 545
+ELECTRICAL SYSTEM INFORMATIONp. 551
Glossary Of Electrical Symbolsp. 551
Standard Cab Harness Connectorsp. 554
Deluxe Cab Harness Connectorsp. 555
Mainframe Harness Connectorsp. 556
Descriptionp. 557
Troubleshootingp. 558
Fuse And Relay Location / Identificationp. 559
Solenoid Testingp. 560
+BATTERYp. 561
Removal And Installationp. 561
Servicingp. 562
Using A Booster Battery (Jump Starting)p. 563
+ALTERNATORp. 565
Belt Adjustmentp. 565
Belt Replacementp. 565
Charging System Inspectionp. 566
Alternator Voltage Testingp. 567
Low Voltage Testingp. 567
High Voltage Testingp. 568
Removal And Installationp. 569
Parts Identificationp. 570
+STARTERp. 571
Testingp. 571
Removal And Installationp. 572
Parts Identificationp. 573
+INSTRUMENT PANELSp. 575
Left Panelp. 575
Standard Key Panelp. 577
Deluxe Instrumentation Panelp. 578
Side Panelp. 579
Front Panelp. 579
Front Panel Removal And Installationp. 580
Removal And Installation (Left And Right)p. 581
Key Switch Removal And Installationp. 583
Alarm Removal And Installationp. 584
+LIGHTSp. 585
Front Removal And Installationp. 585
Rear Removal And Installationp. 586
Cab Light Removal And Installationp. 586
+BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)p. 587
Descriptionp. 587
Connector Identificationp. 588
Removal And Installationp. 590
+BOBCAT CONTROLLER (ACS)p. 591
Descriptionp. 591
Connector And Wire Identificationp. 592
Removal And Installationp. 593
+BOBCAT CONTROLLER (SJC) (DRIVE)p. 595
Descriptionp. 595
Connector Identificationp. 596
Removal And Installationp. 598
+SPEED SENSOR (SJC)p. 601
Descriptionp. 601
Testingp. 601
Removal And Installationp. 603
+DIAGNOSTIC SERVICE CODESp. 607
Viewing Service Codes (Standard Key Panel)p. 607
Viewing Service Codes (Deluxe Instrumentation Panel)p. 607
Service Codes Listp. 608
+BOBCAT INTERLOCK CONTROL SYSTEM (BICS)p. 613
Descriptionp. 613
Inspecting The BICS Controller (Engine STOPPED – Key ON)p. 614
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)p. 614
Inspecting The Seat Bar Sensor (Engine RUNNING)p. 614
Inspecting The Traction Lock (Engine RUNNING)p. 614
Inspecting The Lift Arm Bypass Controlp. 614
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)p. 614
Troubleshootingp. 615
+SEAT BAR SENSORp. 617
Descriptionp. 617
Troubleshootingp. 617
Testingp. 618
Removal And Installationp. 619
Bobcat Interlock Control System (BICS) Circuit Testp. 621
+TRACTION LOCKp. 623
Descriptionp. 623
Troubleshootingp. 624
Inspectingp. 625
+CONTROL SYSTEM (ACS)p. 627
Descriptionp. 627
Troubleshootingp. 628
Handle Sensor Connector Disassembly And Assemblyp. 629
Switch Handle Removalp. 630
Switch Handle Installationp. 632
Actuator Connector Disassembly And Assemblyp. 635
Handle Lock Solenoid Removal And Installationp. 636
Handle Lock Solenoid Disassembly And Assemblyp. 636
Foot Sensor Disassembly And Assemblyp. 637
Foot Lock Solenoid Removal And Installationp. 638
+ELECTRICAL / HYDRAULIC CONTROLSp. 639
Identification Chartp. 639
+ELECTRICAL / HYDRAULIC CONTROLS REFERENCE (SJC)p. 641
Identification Chartp. 641
+SERVICE PC (LAPTOP COMPUTER)p. 645
Connecting Remote Start Toolp. 645
Connecting Remote Start Tool (Service Tool)p. 645
+CALIBRATIONp. 647
Descriptionp. 647
Actuator Testingp. 647
Lift And Tilt Calibration (ACS)p. 649
Lift And Tilt Calibration (SJC)p. 651
Hydrostatic Pump Calibration (SJC)p. 653
+STEERING DRIFT COMPENSATIONp. 659
Descriptionp. 659
Operationp. 659
+FLYWHEEL RPM SENSORp. 661
Descriptionp. 661
Adjustingp. 661
+CONTROL PANEL SETUPp. 663
Right Panel Setup (Deluxe Instrumentation Panel)p. 663
Attachment Control Information (Deluxe Instrumentation Panel)p. 664
+PASSWORD SETUPp. 665
Password Descriptionp. 665
Changing The Owner Passwordp. 665
Changing The User Passwordsp. 666
Password Lockout Featurep. 666
+MAINTENANCE CLOCKp. 667
Descriptionp. 667
Setupp. 668
Resetp. 671
+BACK-UP ALARM SYSTEMp. 673
Descriptionp. 673
Inspectingp. 673
Adjusting Switch Positionp. 674
Troubleshooting (Standard And ACS)p. 675
Troubleshooting (Joystick)p. 676
Alarm Removal And Installationp. 677
Switch Removal And Installationp. 677
+ENGINE SERVICEp. 679
+ENGINE INFORMATIONp. 683
Descriptionp. 683
Specificationsp. 684
Torque Valuesp. 688
Troubleshootingp. 688
Engine Removal And Installationp. 690
Engine Mount Replacementp. 697
Compression – Checkingp. 698
+ENGINE SPEED CONTROLp. 701
Removal And Installationp. 701
+ENGINE SPEED CONTROL (SJC)p. 703
Removal And Installationp. 703
Disassembly And Assemblyp. 705
+MUFFLERp. 707
Removal And Installationp. 707
+AIR CLEANERp. 709
Housing Removal And Installationp. 709
+ENGINE COOLING SYSTEMp. 711
Radiator Removal And Installationp. 711
Hydraulic Fan Descriptionp. 714
Hydraulic Fan Disassembly And Assemblyp. 714
Blower Housing Removal And Installationp. 715
Fan Removal And Installationp. 717
Hydraulic Fan Motor Removal And Installationp. 717
Water Pump Removal And Installationp. 718
Water Pump Disassembly And Assemblyp. 718
Thermostat Housing Removal And Installationp. 719
Thermostat – Checkingp. 720
+LUBRICATION SYSTEMp. 721
Oil Pan Removal And Installationp. 721
Oil Pump Removal And Installationp. 721
Relief Valve – Testingp. 722
Oil Pump Inspectionp. 722
Oil Filter Cooler Removal And Installationp. 723
Engine Oil Pressure – Testingp. 724
+FUEL SYSTEMp. 725
Fuel Shutoff Solenoid – Checkingp. 725
Fuel Shutoff Solenoid Removal And Installationp. 725
Fuel Injection Pump – Checkingp. 726
Fuel Injection Pump Assembly Removal And Installationp. 727
Governor Housing Disassembly And Assemblyp. 730
Governor Disassembly And Assemblyp. 732
Fuel Camshaft Removal And Installationp. 734
Fuel Injection Pump Removal And Installationp. 736
Fuel Injection Pump – Timingp. 738
Fuel Injector Removal And Installationp. 740
Fuel Injector Nozzle Pressure – Checkingp. 741
Nozzle Spray Conditionp. 742
Valve Seat Tightnessp. 742
+CYLINDER HEADp. 743
Glow Plugs – Testingp. 743
Glow Plugs Removal And Installationp. 743
Valve Clearance Adjustmentp. 744
Valve Timing – Checkingp. 745
Cylinder Head Removal And Installationp. 746
Cylinder Head Disassembly and Assemblyp. 749
Cylinder Head – Servicingp. 749
Cylinder Head Top Clearancep. 750
Valve Guide – Checkingp. 750
Valve Guide Removal And Installationp. 751
Reconditioning The Valve And Valve Seatp. 751
Valve Springp. 753
Valve Tappetsp. 754
Rocker Arm And Shaft – Checkingp. 755
Bridge Arm And Bridge Arm Shaft – Checkingp. 755
Bridge Arm Shaft – Removal And Installationp. 756
Push Rod Alignment – Checkingp. 757
+CRANKSHAFT AND PISTONSp. 759
Piston And Connecting Rod Removal And Installationp. 759
Piston And Connecting Rod – Servicingp. 760
Cylinder Bore – Checkingp. 764
Connecting Rod Alignmentp. 765
Crankshaft Gear Removal And Installationp. 765
Crankshaft And Bearings Removal And Installationp. 766
Crankshaft And Bearings – Servicingp. 769
+CAMSHAFT AND TIMING GEARSp. 773
Timing Gearcase Cover Removalp. 773
Timing Gearcase Cover Installationp. 774
Timing Gears Backlash – Checkingp. 777
Idler Gear And Camshaft Removal And Installationp. 777
Camshaft – Servicingp. 778
Idler Gear And Shaft – Servicingp. 779
+TURBOCHARGERp. 781
Descriptionp. 781
Testingp. 781
Removal And Installationp. 782
+FLYWHEEL AND HOUSINGp. 783
Flywheel Removal And Installationp. 783
Ring Gear Removal And Installationp. 784
Housing Removal And Installationp. 785
+EXHAUST GAS RECIRCULATION (EGR) SYSTEMp. 787
Descriptionp. 787
Testingp. 788
Removal And Installationp. 791
Disassembly And Assemblyp. 792
+HEATING, VENTILATION, AIR CONDITIONINGp. 793
+AIR CONDITIONING SYSTEM FLOWp. 796
Descriptionp. 796
Chartp. 797
Componentsp. 798
Safety Equipmentp. 801
+REGULAR MAINTENANCEp. 803
Filtersp. 803
Compressor Drive Belt Adjustmentp. 804
Compressor Drive Belt Replacementp. 805
Condenserp. 805
Air Conditioning Lubricationp. 805
Air Conditioning Service Chartp. 806
Evaporator / Heater Coilp. 807
+TROUBLESHOOTINGp. 809
Blower Motor Does Not Operatep. 809
Blower Motor Operates Normally, But Air Flow Is Insufficientp. 809
Insufficient Cooling Although Air Flow And Compressor Operation Are Normalp. 809
The Compressor Does Not Operate At All, Or Operates Improperlyp. 809
Gauge Pressure Related Troubleshootingp. 810
Troubleshooting Treep. 812
Temperature / Pressure Chartp. 816
Poor A/C Performancep. 817
HVAC Repair And Leaksp. 818
Electrical Systemp. 819
Engine Coolant Bypassing The Heater Valvep. 827
Heater Valve Not Opening Or Closingp. 828
+SYSTEM CHARGING AND RECLAMATIONp. 829
Refrigerant Identificationp. 829
Reclamation And Charging With Recovery / Charging Unitp. 830
Charging With A Manifold Gauge Setp. 832
+COMPRESSORp. 835
Removal And Installationp. 835
Oilp. 836
Oil Checkp. 837
Clutch Disassembly And Asssemblyp. 839
+CONDENSERp. 843
Removal And Installationp. 843
+RECEIVER / DRIERp. 845
Receiver / Drier Removal And Installationp. 845
Pressure Relief Valve Removal And Installationp. 846
Pressure Switch Removal And Installationp. 847
Schraeder Valve Removal And Installationp. 848
+EVAPORATOR / HEATER UNITp. 849
Removal And Installationp. 849
+THERMOSTATp. 851
Removal And Installationp. 851
+EXPANSION VALVEp. 853
Removal And Installationp. 853
+EVAPORATOR COILp. 855
Removal And Installationp. 855
+HEATER COILp. 857
Removal And Installation With A/Cp. 857
Removal And Installation Without A/Cp. 859
+BLOWER FANp. 861
Removal And Installationp. 861
Disassembly And Assemblyp. 862
Connector Identificationp. 864
+HEATER VALVEp. 865
Removal And Installationp. 865
Disassembly And Assemblyp. 866
+SPECIFICATIONSp. 867
+(T190) LOADER SPECIFICATIONSp. 869
Machine Dimensionsp. 869
Performancep. 870
Enginep. 870
Controlsp. 870
Drive Systemp. 871
Hydraulic Systemp. 871
Electricalp. 872
Capacitiesp. 872
Tracksp. 872
Ground Pressurep. 872
+TORQUE SPECIFICATIONS FOR BOLTSp. 873
Torque For General SAE Boltsp. 873
Torque For General Metric Boltsp. 874
+HYDRAULIC CONNECTION SPECIFICATIONSp. 875
O-ring Face Seal Connectionp. 875
Straight Thread O-ring Fittingp. 876
Tubelines And Hosesp. 876
Flare Fittingp. 877
Port Seal Fittingp. 878
+HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONSp. 879
+CONVERSIONSp. 881
Decimal And Millimeter Equivalentsp. 881
U.S. To Metric Conversion Chartp. 881
+SMRp. 883
T190-1p. 883
T190-2p. 885
T190-3p. 887
- Electrical System & Analysis
- Electrical-system information, symbols, harness connectors, fuses and relays
- Alternator, battery, starter, lights and instrument-panel service
- Bobcat Interlock Control System (BICS) inspection and troubleshooting
- ACS, gateway/auxiliary and SJC drive controllers
- Diagnostic service codes and electrical/hydraulic control references
- ACS/SJC calibration, hydrostatic pump calibration and steering drift compensation
- Seat-bar, speed and flywheel RPM sensors; traction lock and back-up alarm
- Service PC connection, control-panel setup, maintenance clock and password functions
- Engine Service
- Engine information, specifications, torque values, compression checking and removal/installation
- Fuel injection pump, injectors, governor and fuel-shutoff components
- Cylinder head, valve clearance, valve guides, valve seats, rocker arms and glow plugs
- Crankshaft, pistons, connecting rods, bearings and cylinder-bore checks
- Camshaft, timing gears and timing gearcase service
- Cooling system, hydraulic fan, radiator, thermostat and water pump
- Lubrication system, oil pump, oil cooler/filter and oil-pressure testing
- EGR system, flywheel/housing, muffler and turbocharger
- Heating, Ventilation, Air Conditioning
- A/C system flow, component descriptions and safety equipment
- Compressor, condenser, evaporator/heater unit, evaporator coil and expansion valve
- Receiver/drier, pressure relief and pressure switch procedures
- Heater coil, heater valve, blower fan and thermostat
- Regular maintenance, refrigerant identification, charging and reclamation
- A/C and heater troubleshooting with pressure/temperature references
- Specifications
- T190 machine dimensions, performance, engine and control specifications
- Drive-system, hydraulic-system and electrical data
- Fuel, engine, cooling and hydraulic/hydrostatic capacities
- Track and ground-pressure information
- Hydraulic connection and hydraulic/hydrostatic fluid specifications
- General SAE and metric bolt torque specifications and conversion charts
Taken as a whole, the manual gives a technician a single structured reference for identifying the machine, carrying out scheduled service, isolating common system faults, testing components, removing and rebuilding major assemblies, setting pressures and adjustments, and checking the specifications needed to return the loader to service correctly. The depth ranges from basic fluid and filter procedures to pump, control-valve, engine and electronic-control work.
Built for T190 Repair and Service Work
The Bobcat T190 Compact Track Loader Service Manual 6987052 – A3LN11001/A3LP11001 & Above supports real maintenance, diagnosis and repair jobs on the covered T190 loaders, including hydraulic and hydrostatic troubleshooting, track and brake service, electrical diagnosis, engine repair, control calibration and HVAC work. Having the correct procedure, pressure, torque, clearance, capacity and adjustment information matters when a job goes beyond routine checks and into component testing or overhaul. Your purchase is delivered as an instant PDF download with no shipping required; it can be opened on compatible phones, tablets and computers and printed for workshop reference.
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