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Bobcat T190 Compact Track Loader Service Manual 6987052 – PDF DOWNLOAD
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Bobcat T190 Compact Track Loader Service Manual 6987052 – PDF DOWNLOAD
S/N A3LN11001 & Above
S/N A3LP11001 & Above
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Description
Bobcat T190 Compact Track Loader Service Manual 6987052 – PDF DOWNLOAD
FILE DETAILS:
Bobcat T190 Compact Track Loader Service Manual 6987052 – PDF DOWNLOAD
Language : English
Pages : 1002
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T190 Compact Track Loader Service Manual 6987052 – PDF DOWNLOAD
S/N A3LN11001 & Above
S/N A3LP11001 & 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 6987052 – PDF DOWNLOAD
MAINTENANCE SAFETY.................................................................................... 3 CONTENTS.............................................................................................. 5 FOREWORD.............................................................................................. 7 FOREWORD.......................................................................................... 9 SAFETY INSTRUCTIONS............................................................................... 12 FIRE PREVENTION................................................................................... 14 Maintenance................................................................................... 14 Operation..................................................................................... 14 Electrical.................................................................................... 14 Hydraulic System.............................................................................. 14 Fueling....................................................................................... 14 Starting...................................................................................... 14 Spark Arrester Exhaust System................................................................. 14 Welding And Grinding.......................................................................... 15 Fire Extinguishers............................................................................ 15 SERIAL NUMBER LOCATION............................................................................ 16 Loader Serial Number.......................................................................... 16 Engine Serial Number.......................................................................... 16 DELIVERY REPORT................................................................................... 17 LOADER IDENTIFICATION............................................................................. 18 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 Communicator - MEL1566................................................... 35 Remote Start Procedure........................................................................ 36 REMOTE START TOOL (SERVICE TOOL) KIT - 7003031.................................................... 39 Description................................................................................... 39 Remote Start Tool (Service Tool) - 7003030.................................................... 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......................................................... 58 HYDRAULIC / HYDROSTATIC SYSTEM.................................................................... 59 Checking And Adding Fluid..................................................................... 59 Hydraulic / Hydrostatic Fluid Chart........................................................... 59 Removing And Replacing Hydraulic Fluid........................................................ 60 Removing And Replacing Hydraulic / Hydrostatic Filter......................................... 61 Removing And Replacing Case Drain Filters..................................................... 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............................................................................ 73 Cleaning Procedure............................................................................ 73 PIVOT PINS........................................................................................ 75 Inspection And Maintenance.................................................................... 75 LOADER STORAGE AND RETURN TO SERVICE.............................................................. 77 Storage....................................................................................... 77 Return To Service............................................................................. 77 STOPPING THE ENGINE AND LEAVING THE LOADER........................................................ 79 Procedure..................................................................................... 79 EMERGENCY EXIT.................................................................................... 81 Rear Window................................................................................... 81 Front Door.................................................................................... 81 SEAT BELT......................................................................................... 83 Inspection And Maintenance.................................................................... 83 HYDRAULIC SYSTEM...................................................................................... 85 HYDRAULIC/HYDROSTATIC SCHEMATICS.................................................................. 91 HYDRAULIC SYSTEM INFORMATION...................................................................... 99 Glossary Of Hydraulic / Hydrostatic Symbols................................................... 99 Troubleshooting...............................................................................103 CYLINDER (LIFT)...................................................................................105 Testing.......................................................................................105 Removal And Installation......................................................................106 Parts Identification..........................................................................109 Disassembly And Assembly......................................................................110 CYLINDER (TILT)...................................................................................113 Testing.......................................................................................113 Removal And Installation......................................................................114 Rod End Pivot Pin Bushing And Seal Removal And Installation...................................116 Base End Pivot Pin Removal And Installation...................................................116 Parts Identification..........................................................................117 Disassembly And Assembly......................................................................118 CYLINDER (BOB-TACH)...............................................................................121 Testing.......................................................................................121 Removal And Installation......................................................................122 Parts Identification..........................................................................123 Disassembly And Assembly......................................................................124 MAIN RELIEF VALVE.................................................................................127 Description...................................................................................127 Testing.......................................................................................127 Adjusting.....................................................................................129 Removal And Installation......................................................................130 HYDRAULIC CONTROL VALVE (STANDARD)................................................................131 Description...................................................................................131 Removal And Installation......................................................................132 Identification Chart..........................................................................137 Mount Bracket Removal And Installation........................................................138 Lift Load Check Valve Removal And Installation................................................138 Load Check Valve Removal And Installation (Tilt And Auxiliary)................................139 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)................................140 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End).................141 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End).................141 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)..................142 Port Relief Valve Removal And Installation....................................................142 Plug Removal And Installation.................................................................143 Rubber Boot Removal And Installation..........................................................144 End Cap / Spool Lock Block Removal And Installation...........................................145 Lift Spool And Detent Removal And Installation................................................146 Tilt Spool Removal And Installation...........................................................156 Auxiliary Spool Removal And Installation......................................................158 Auxiliary Solenoid Removal And Installation (S/N A3LN34999 & Below And A3LP34999 & Below).....160 Auxiliary Solenoid Removal And Installation (S/N A3LN35001 & Above And A3LP35001 & Above).....161 Solenoid Removal And Installation.............................................................162 Lock Valve Removal And Installation...........................................................163 Lift Arm Bypass Orifice Removal And Installation..............................................165 Main Relief Valve Removal And Installation....................................................165 Check Valve Removal And Installation..........................................................166 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)............................................................167 Description...................................................................................167 Removal And Installation......................................................................168 Actuator Removal And Installation (Out of Loader).............................................172 Identification Chart..........................................................................175 Mount Bracket Removal And Installation........................................................176 Lift Load Check Valve Removal And Installation................................................176 Load Check Valve Removal And Installation (Tilt And Auxiliary)................................177 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)................................178 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End).................179 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End).................179 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)..................180 Port Relief Valve Removal And Installation....................................................180 Plug Removal And Installation.................................................................181 End Cap Block Removal And Installation........................................................182 Lift Spool And Detent Removal And Installation................................................183 Tilt Spool Removal And Installation...........................................................188 Auxiliary Spool Removal And Installation......................................................190 Auxiliary Solenoid Removal And Installation (S/N A3LN34999 & Below And A3LP34999 & Below).....192 Auxiliary Solenoid Removal And Installation (S/N A3LN35001 & Above And A3LP35001 & Above).....193 Solenoid Removal And Installation.............................................................194 Lock Valve Removal And Installation...........................................................195 Lift Arm Bypass Orifice Removal And Installation..............................................197 Main Relief Valve Removal And Installation....................................................197 Check Valve Removal And Installation..........................................................198 LIFT ARM BYPASS CONTROL VALVE.....................................................................199 Description...................................................................................199 Testing.......................................................................................199 Removal And Installation......................................................................199 Disassembly And Assembly......................................................................200 HYDRAULIC PUMP (STANDARD).........................................................................201 Description...................................................................................201 Pump Test At Quick Couplers...................................................................201 Direct Pump Test (Standard Section)...........................................................202 Direct Pump Test (Charge Section).............................................................204 Removal And Installation......................................................................206 Hydraulic Pump Startup........................................................................208 Parts Identification..........................................................................209 Disassembly And Assembly......................................................................210 HYDRAULIC PUMP (STANDARD) (HIGH FLOW).............................................................219 Description...................................................................................219 Pump Test At Quick Couplers...................................................................219 Direct Pump Test (Standard Section)...........................................................220 Direct Pump Test (Charge Section).............................................................222 Direct Pump Test (High Flow Section)..........................................................224 Removal And Installation......................................................................226 Hydraulic Pump Startup........................................................................228 Parts Identification..........................................................................229 Disassembly And Assembly......................................................................230 HYDRAULIC PUMP (SJC)..............................................................................243 Description...................................................................................243 Pump Test At Quick Couplers...................................................................243 Direct Pump Test (Standard Section)...........................................................244 Direct Pump Test (Charge Section).............................................................246 Removal And Installation......................................................................248 Hydraulic Pump Startup........................................................................250 Parts Identification..........................................................................251 Disassembly And Assembly......................................................................252 HYDRAULIC PUMP (SJC) (HIGH FLOW)..................................................................261 Description...................................................................................261 Pump Test At Quick Couplers...................................................................261 Direct Pump Test (Standard Section)...........................................................262 Direct Pump Test (Charge Section).............................................................264 Direct Pump Test (High Flow Section)..........................................................266 Removal And Installation......................................................................268 Hydraulic Pump Startup........................................................................270 Parts Identification..........................................................................271 Disassembly And Assembly......................................................................272 HYDRAULIC / HYDROSTATIC FILTERS...................................................................285 Description...................................................................................285 Housing Removal And Installation..............................................................285 Charge Filter Housing Removal And Installation................................................287 HYDRAULIC FLUID RESERVOIR.........................................................................289 Description...................................................................................289 Removal And Installation......................................................................289 Hydraulic Fluid Screen........................................................................291 OIL COOLER........................................................................................293 Description...................................................................................293 Removal And Installation......................................................................293 BUCKET POSITION VALVE.............................................................................295 Description...................................................................................295 Solenoid Removal And Installation.............................................................295 Solenoid Testing..............................................................................296 Removal And Installation......................................................................297 Disassembly And Assembly......................................................................298 REAR AUXILIARY DIVERTER VALVE.....................................................................301 Description...................................................................................301 Solenoid Testing..............................................................................301 Removal And Installation......................................................................302 Disassembly And Assembly......................................................................305 BOB-TACH (POWER) BLOCK............................................................................311 Description...................................................................................311 Removal And Installation......................................................................311 Disassembly And Assembly......................................................................313 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK...........................................................317 Description...................................................................................317 Removal And Installation......................................................................317 Disassembly And Assembly......................................................................317 HIGH FLOW VALVE...................................................................................319 Description...................................................................................319 High Flow Relief Valve Testing................................................................319 High Flow Relief Valve Adjustment.............................................................321 Solenoid Testing..............................................................................322 Removal And Installation......................................................................323 Disassembly And Assembly......................................................................324 HYDROSTATIC SYSTEM....................................................................................327 HYDROSTATIC SYSTEM INFORMATION....................................................................329 Description...................................................................................329 Troubleshooting...............................................................................330 HYDROSTATIC DRIVE MOTOR (A3LN35196 & BELOW, A3LP35009 & BELOW)....................................331 Description...................................................................................331 Removing And Replacing Oil....................................................................332 Removal And Installation......................................................................334 Parts Identification..........................................................................336 Disassembly And Assembly......................................................................338 HYDROSTATIC DRIVE MOTOR (A3LN35197 - A3LN36499, A3LP35010 - A3LP36499)............................349 Description...................................................................................349 Removing And Replacing Oil....................................................................350 Removal And Installation......................................................................352 Parts Identification..........................................................................354 Disassembly And Assembly......................................................................356 HYDROSTATIC DRIVE MOTOR (A3LN36500 & ABOVE, A3LP36500 & ABOVE)....................................367 Description...................................................................................367 Removing And Replacing Oil....................................................................368 Removal And Installation......................................................................370 Parts Identification..........................................................................372 Disassembly And Assembly......................................................................374 CHARGE PRESSURE...................................................................................385 Description...................................................................................385 Testing (S/N A3LN29999 & Below And A3LP29999 & Below).........................................386 Sender Removal And Installation (S/N A3LN29999 & Below And A3LP29999 & Below).................387 Testing (S/N A3LN30001 & Above And A3LP30001 & Above).........................................388 Sender Removal And Installation (S/N A3LN30001 & Above And A3LP30001 & Above).................389 Adjusting.....................................................................................390 HYDROSTATIC PUMP..................................................................................393 Description...................................................................................393 Replenishing / High Pressure Relief Valve Removal And Installation............................394 Removal And Installation......................................................................395 Hydrostatic Pump Startup......................................................................397 Parts Identification (Left Half)..............................................................398 Parts Identification (Right Half).............................................................399 Disassembly...................................................................................400 Assembly......................................................................................406 HYDROSTATIC PUMP (SJC)............................................................................413 Description...................................................................................413 Hydraulic Controller Removal And Installation.................................................414 Removal And Installation......................................................................416 Hydrostatic Pump Startup......................................................................418 Parts Identification..........................................................................419 High Pressure Relief And Bypass Valve.........................................................420 Charge Relief Valve...........................................................................421 Disassembly And Assembly......................................................................422 Mechanical Neutral Adjustment.................................................................438 Hydraulic Controller Neutral Adjustment.......................................................441 DRIVE BELT........................................................................................445 Description...................................................................................445 Shield Removal And Installation...............................................................445 Adjusting.....................................................................................446 Belt Removal And Installation.................................................................447 Tensioner Pulley Removal And Installation.....................................................448 Tensioner Pulley Parts Identification.........................................................449 Tensioner Pulley Disassembly..................................................................450 Tensioner Pulley Assembly.....................................................................451 CASE DRAIN FILTER.................................................................................453 Description...................................................................................453 Disassembly And Assembly......................................................................453 DRIVE SYSTEM..........................................................................................455 BRAKE.............................................................................................457 Description...................................................................................457 Right Motor Brake Test........................................................................457 Left Motor Brake Test.........................................................................458 Block Removal And Installation................................................................459 Block Disassembly And Assembly................................................................461 TRACK UNDERCARRIAGE (SOLID-mOUNTED) (S/N A3LN35235, A3LP35010 & BELOW)............................463 Description...................................................................................463 Checking Tension..............................................................................464 Adjusting Tension.............................................................................464 Track Removal And Installation................................................................466 Track Tensioner Disassembly And Assembly......................................................471 Idler (Rear) Removal And Installation.........................................................472 Roller Removal And Installation...............................................................472 Sprocket Removal And Installation.............................................................473 Track Housing Removal And Installation........................................................474 TRACK UNDERCARRIAGE (SOLID-MOUNTED) (S/N A3LN35236, A3LP35011 & ABOVE)............................477 Description...................................................................................477 Checking Tension..............................................................................478 Adjusting Tension.............................................................................479 Track Removal And Installation................................................................480 Idler (Front) Removal And Installation........................................................482 Idler (Rear) Removal And Installation.........................................................487 Roller Removal And Installation...............................................................487 Sprocket Removal And Installation.............................................................488 Track Housing Removal And Installation........................................................489 TRACK UNDERCARRIAGE (ROLLER SUSPENSION)...........................................................491 Description...................................................................................491 Checking Tension..............................................................................492 Adjusting Tension.............................................................................493 Track Removal And Installation................................................................494 Idler (Front) Removal And Installation........................................................496 Track Tensioner Disassembly And Assembly......................................................500 Idler (Rear) Removal And Installation.........................................................501 Roller Removal And Installation...............................................................501 Leaf Spring Removal And Installation..........................................................502 Sprocket Removal And Installation.............................................................503 Track Housing Removal And Installation........................................................504 TRACK MAINTENANCE.................................................................................507 Track Damage Identification...................................................................507 MAINFRAME.............................................................................................519 SEAT BAR..........................................................................................523 Description...................................................................................523 Removal And Installation......................................................................523 Disassembly And Assembly......................................................................524 Compression Spring Disassembly And Assembly...................................................525 OPERATOR CAB......................................................................................527 Gas Cylinder Removal And Installation.........................................................527 Gas Cylinder Bracket Disassembly And Assembly.................................................529 Removal And Installation......................................................................530 OPERATOR SEAT (SUSPENSION)........................................................................533 Removal And Installation......................................................................533 Slide Rail Removal And Installation...........................................................534 Seat Belt Removal And Installation............................................................534 Lower Cushion Removal And Installation........................................................534 Back Cushion Removal And Installation.........................................................536 Shock Removal And Installation................................................................536 3-Point Seat Belt Removal And Installation....................................................537 BOB-TACH (HAND LEVER).............................................................................539 Description...................................................................................539 Removal And Installation......................................................................539 Lever And Wedge Disassembly And Assembly......................................................540 Pivot Pin Bushing And Seal Removal And Installation...........................................542 BOB-TACH (POWER)..................................................................................543 Description...................................................................................543 Removal And Installation......................................................................543 Lever And Wedge Disassembly And Assembly......................................................545 Pivot Pin Bushing And Seal Removal And Installation...........................................546 LIFT ARMS.........................................................................................547 Stabilizer Bar Removal And Installation.......................................................547 Link Removal And Installation.................................................................548 Removal And Installation......................................................................549 REAR GRILLE.......................................................................................553 Removal And Installation......................................................................553 REAR DOOR (TAILGATE)..............................................................................555 Removal And Installation......................................................................555 Striker Removal And Installation..............................................................556 Striker Disassembly And Assembly..............................................................556 Striker (Adjusting)...........................................................................557 Latch Removal And Installation................................................................558 FUEL TANK.........................................................................................559 Removal And Installation......................................................................559 Fuel Level Sender Removal And Installation....................................................560 Fuel Fill Screen Removal And Installation.....................................................560 CONTROL PEDALS AND LINKAGES.......................................................................561 Description...................................................................................561 Pedal Removal And Installation................................................................561 Linkage Removal And Installation..............................................................562 Pedal (Adjusting).............................................................................564 CONTROL PEDALS (ACS)..............................................................................565 Description...................................................................................565 Foot Sensor Removal And Installation..........................................................565 Foot Pedal Removal And Installation...........................................................566 Foot Pedal Linkage Disassembly And Assembly...................................................567 CONTROL PANEL.....................................................................................569 Description...................................................................................569 Removal And Installation......................................................................570 Shock Removal And Installation................................................................573 Shaft Removal And Installation................................................................573 Shaft Disassembly And Assembly................................................................574 Linkage Removal And Installation..............................................................575 Pintle Arm Disassembly And Assembly...........................................................579 Linkage Neutral (Adjusting)...................................................................581 Linkage Travel (Adjusting)....................................................................585 CONTROL PANEL (SJC)...............................................................................589 Description...................................................................................589 Removal And Installation......................................................................589 CONTROL HANDLE / LEVER............................................................................591 Description...................................................................................591 Lever Removal And Installation................................................................591 Boot Removal And Installation.................................................................592 CONTROL HANDLE / LEVER (ACS)......................................................................593 Description...................................................................................593 Handle Sensor Removal And Installation........................................................593 Handle Removal And Installation...............................................................596 Handle Disassembly And Assembly...............................................................597 Lever Removal And Installation................................................................597 Boot Removal And Installation.................................................................599 CONTROL HANDLE / LEVER (SJC)......................................................................601 Description...................................................................................601 Joystick Testing..............................................................................601 Joystick Removal And Installation.............................................................602 Joystick Mount Removal And Installation.......................................................606 ACCESS PANEL (INSIDE).............................................................................609 Removal And Installation (Left)...............................................................609 Removal And Installation (Right)..............................................................609 ACCESS PANEL (INSIDE) (SJC).......................................................................611 Removal And Installation (Left)...............................................................611 Removal And Installation (Right)..............................................................612 WINDOW (REAR).....................................................................................615 Removal.......................................................................................615 Installation (Split Molding)..................................................................615 Installation (Continuous Molding).............................................................617 WINDOW (TOP)......................................................................................619 Removal And Installation......................................................................619 WINDOW (SIDE).....................................................................................621 Removal And Installation......................................................................621 WINDOW (CAB DOOR).................................................................................623 Removal (Standard Window).....................................................................623 Installation (Standard Window)................................................................624 Removal And Installation (Special Applications Window)........................................626 CAB DOOR..........................................................................................627 Description...................................................................................627 Removal And Installation......................................................................627 Aligning......................................................................................628 Adjusting.....................................................................................629 Checking Operation............................................................................629 ELECTRICAL SYSTEM & ANALYSIS..........................................................................631 ELECTRICAL SCHEMATICS.............................................................................635 ELECTRICAL SYSTEM INFORMATION.....................................................................641 Glossary Of Electrical Symbols................................................................641 Standard Cab Harness Connectors...............................................................644 Deluxe Cab Harness Connectors.................................................................645 Mainframe Harness Connectors..................................................................646 Description...................................................................................647 Troubleshooting...............................................................................648 Fuse And Relay Location / Identification......................................................649 Solenoid Testing..............................................................................650 BATTERY...........................................................................................651 Removal And Installation......................................................................651 Servicing.....................................................................................652 Using A Booster Battery (Jump Starting).......................................................653 ALTERNATOR........................................................................................655 Belt Adjustment...............................................................................655 Belt Replacement..............................................................................655 Charging System Inspection....................................................................656 Alternator Voltage Testing....................................................................657 Low Voltage Testing...........................................................................657 High Voltage Testing..........................................................................658 Removal And Installation......................................................................659 Parts Identification..........................................................................660 STARTER...........................................................................................661 Testing.......................................................................................661 Removal And Installation......................................................................662 Parts Identification..........................................................................663 INSTRUMENT PANELS.................................................................................665 Left Panel....................................................................................665 Standard Key Panel............................................................................667 Keyless Start Panel...........................................................................667 Deluxe Instrumentation Panel..................................................................668 Side Panel....................................................................................669 Front Panel...................................................................................669 Front Panel Removal And Installation..........................................................670 Removal And Installation (Left And Right).....................................................671 Key Switch Removal And Installation...........................................................673 Alarm Removal And Installation................................................................674 LIGHTS............................................................................................675 Front Removal And Installation................................................................675 Rear Removal And Installation.................................................................676 Cab Light Removal And Installation............................................................676 BOBCAT CONTROLLER (GATEWAY AND AUXILIARY).........................................................677 Description...................................................................................677 Connector Identification......................................................................678 Removal And Installation......................................................................684 BOBCAT CONTROLLER (ACS)...........................................................................687 Description...................................................................................687 Connector And Wire Identification.............................................................688 Removal And Installation......................................................................689 BOBCAT CONTROLLER (SJC) (DRIVE)...................................................................691 Description...................................................................................691 Connector Identification......................................................................692 Removal And Installation......................................................................694 SPEED SENSORS (SJC)...............................................................................695 Description...................................................................................695 Testing.......................................................................................695 Removal And Installation......................................................................697 DIAGNOSTIC SERVICE CODES..........................................................................701 Viewing Service Codes.........................................................................701 Service Codes List............................................................................702 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)...........................................................707 Description...................................................................................707 Inspecting The BICS™ (Engine STOPPED - Key ON)................................................708 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)..........708 Inspecting The Seat Bar Sensor (Engine RUNNING)...............................................708 Inspecting The Traction Lock (Engine RUNNING).................................................708 Inspecting The Lift Arm Bypass Control........................................................708 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)..............................708 Troubleshooting...............................................................................709 SEAT BAR SENSOR...................................................................................711 Description...................................................................................711 Troubleshooting...............................................................................711 Testing.......................................................................................712 Removal And Installation......................................................................713 Bobcat Interlock Control System (BICS™) Circuit Test..........................................716 TRACTION LOCK.....................................................................................719 Description...................................................................................719 Troubleshooting...............................................................................720 Inspecting....................................................................................721 CONTROL SYSTEM (ACS)..............................................................................723 Description...................................................................................723 Troubleshooting...............................................................................724 Handle Sensor Connector Disassembly And Assembly..............................................725 Switch Handle Removal.........................................................................726 Switch Handle Installation....................................................................728 Actuator Connector Disassembly And Assembly...................................................731 Handle Lock Solenoid Removal And Installation.................................................732 Handle Lock Solenoid Disassembly And Assembly.................................................732 Foot Sensor Disassembly And Assembly..........................................................733 Foot Lock Solenoid Removal And Installation...................................................734 ELECTRICAL / HYDRAULIC CONTROLS...................................................................735 Identification Chart..........................................................................735 Description...................................................................................736 Identification Chart ACD Group 0..............................................................737 Identification Chart ACD Group 1..............................................................738 Identification Chart ACD Group 2..............................................................739 Identification Chart ACD Group 3..............................................................740 ELECTRICAL / HYDRAULIC CONTROLS (ACS).............................................................741 Identification Chart..........................................................................741 Description...................................................................................742 Identification Chart ACD Group 0..............................................................743 Identification Chart ACD Group 1..............................................................744 Identification Chart ACD Group 2..............................................................745 Identification Chart ACD Group 3..............................................................746 ELECTRICAL / HYDRAULIC CONTROLS (SJC).............................................................747 Identification Chart..........................................................................747 Description...................................................................................748 Identification Chart ACD Group 0..............................................................749 Identification Chart ACD Group 1..............................................................750 Identification Chart ACD Group 2..............................................................751 Identification Chart ACD Group 3..............................................................752 SERVICE PC (LAPTOP COMPUTER)......................................................................753 Connecting Remote Start Tool..................................................................753 Connecting Remote Start Tool (Service Tool)...................................................753 CALIBRATION.......................................................................................755 Description...................................................................................755 Actuator Testing..............................................................................755 Lift And Tilt Calibration (SJC)...............................................................758 Hydrostatic Pump Calibration (SJC)............................................................760 Lift And Tilt Calibration (ACS)...............................................................765 STEERING DRIFT COMPENSATION.......................................................................767 Description...................................................................................767 Operation.....................................................................................767 FLYWHEEL RPM SENSOR...............................................................................769 Description...................................................................................769 Adjusting.....................................................................................769 CONTROL PANEL SETUP...............................................................................771 Right Panel Setup (Deluxe Instrumentation Panel)..............................................771 Attachment Control Information (Deluxe Instrumentation Panel).................................772 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL).....................................................773 Password Description..........................................................................773 Changing The Owner Password...................................................................773 Changing The User Passwords...................................................................774 Password Lockout Feature......................................................................774 PASSWORD SETUP (KEYLESS START PANEL)..............................................................775 Password Description..........................................................................775 Changing The Owner Password...................................................................775 Password Lockout Feature......................................................................775 MAINTENANCE CLOCK.................................................................................777 Description...................................................................................777 Setup.........................................................................................778 Reset.........................................................................................781 BACK-UP ALARM SYSTEM..............................................................................783 Description...................................................................................783 Inspecting....................................................................................783 Adjusting Switch Position.....................................................................784 Troubleshooting (Standard And ACS)............................................................785 Troubleshooting (Joystick)....................................................................786 Alarm Removal And Installation................................................................787 Switch Removal And Installation...............................................................787 ENGINE SERVICE........................................................................................789 ENGINE INFORMATION................................................................................793 Description...................................................................................793 Specifications................................................................................794 Torque Values.................................................................................798 Troubleshooting...............................................................................798 Engine Removal And Installation...............................................................800 Engine Mount Replacement......................................................................807 Compression - Checking........................................................................808 ENGINE SPEED CONTROL..............................................................................809 Removal And Installation......................................................................809 ENGINE SPEED CONTROL (SJC)........................................................................811 Removal And Installation......................................................................811 Disassembly And Assembly......................................................................813 MUFFLER...........................................................................................815 Removal And Installation......................................................................815 AIR CLEANER.......................................................................................817 Housing Removal And Installation..............................................................817 ENGINE COOLING SYSTEM.............................................................................819 Radiator Removal And Installation.............................................................819 Hydraulic Fan Description (S/N A3LN29999 & Below And A3LP29999 & Below).......................822 Hydraulic Fan Disassembly And Assembly (S/N A3LN29999 & Below And A3LP29999 & Below)..........822 Blower Housing Removal And Installation (S/N A3LN29999 & Below And A3LP29999 & Below).........823 Fan Removal And Installation (S/N A3LN29999 & Below And A3LP29999 & Below)....................825 Hydraulic Fan Motor Removal And Installation (S/N A3LN29999 & Below And A3LP29999 & Below)....825 Hydraulic Fan Description (S/N A3LN30001 & Above And A3LP30001 & Above).......................826 Hydraulic Fan Disassembly And Assembly (S/N A3LN30001 & Above And A3LP30001 & Above)..........826 Blower Housing Removal And Installation (S/N A3LN30001 & Above And A3LP30001 & Above).........828 Fan Removal And Installation (S/N A3LN30001 & Above And A3LP30001 & Above)....................830 Hydraulic Fan Motor Removal And Installation (S/N A3LN30001 & Above And A3LP30001 & Above)....830 Water Pump Removal And Installation...........................................................831 Water Pump Disassembly And Assembly...........................................................831 Thermostat Housing Removal And Installation...................................................832 Thermostat - Checking.........................................................................833 LUBRICATION SYSTEM................................................................................835 Oil Pan Removal And Installation..............................................................835 Oil Pump Removal And Installation.............................................................835 Relief Valve - Testing........................................................................836 Oil Pump Inspection...........................................................................836 Oil Filter Cooler Removal And Installation....................................................837 Engine Oil Pressure - Testing.................................................................838 FUEL SYSTEM.......................................................................................839 Fuel Shutoff Solenoid - Checking..............................................................839 Fuel Shutoff Solenoid Removal And Installation................................................839 Fuel Injection Pump - Checking................................................................840 Fuel Injection Pump Assembly Removal And Installation.........................................841 Governor Housing Disassembly And Assembly.....................................................844 Governor Disassembly And Assembly.............................................................846 Fuel Camshaft Removal And Installation........................................................848 Fuel Injection Pump Removal And Installation..................................................851 Fuel Injection Pump - Timing..................................................................853 Fuel Injector Removal And Installation........................................................855 Fuel Injector Nozzle Pressure - Checking......................................................856 Nozzle Spray Condition........................................................................857 Valve Seat Tightness..........................................................................857 CYLINDER HEAD.....................................................................................859 Glow Plugs - Testing..........................................................................859 Glow Plugs Removal And Installation...........................................................859 Valve Clearance Adjustment....................................................................860 Valve Timing - Checking.......................................................................861 Cylinder Head Removal And Installation........................................................862 Cylinder Head Disassembly and Assembly........................................................865 Cylinder Head - Servicing.....................................................................865 Cylinder Head Top Clearance...................................................................866 Valve Guide - Checking........................................................................866 Valve Guide Removal And Installation..........................................................867 Reconditioning The Valve And Valve Seat.......................................................867 Valve Spring..................................................................................869 Valve Tappets.................................................................................870 Rocker Arm And Shaft - Checking...............................................................871 Bridge Arm And Bridge Arm Shaft - Checking....................................................871 Bridge Arm Shaft Removal And Installation.....................................................872 Push Rod Alignment - Checking.................................................................873 CRANKSHAFT AND PISTONS............................................................................875 Piston And Connecting Rod Removal And Installation............................................875 Piston And Connecting Rod - Servicing.........................................................876 Cylinder Bore - Checking......................................................................880 Connecting Rod Alignment......................................................................881 Crankshaft Gear Removal And Installation......................................................881 Crankshaft And Bearings Removal And Installation..............................................882 Crankshaft And Bearings - Servicing...........................................................885 CAMSHAFT AND TIMING GEARS.........................................................................889 Timing Gearcase Cover Removal.................................................................889 Timing Gearcase Cover Installation............................................................890 Timing Gears Backlash - Checking..............................................................893 Idler Gear And Camshaft Removal And Installation..............................................893 Camshaft - Servicing..........................................................................894 Idler Gear And Shaft - Servicing..............................................................895 TURBOCHARGER......................................................................................897 Description...................................................................................897 Testing.......................................................................................897 Removal And Installation......................................................................898 FLYWHEEL AND HOUSING..............................................................................899 Flywheel Removal And Installation.............................................................899 Ring Gear Removal And Installation............................................................900 Housing Removal And Installation..............................................................901 EXHAUST GAS RECIRCULATION (EGR) SYSTEM............................................................903 Description...................................................................................903 Testing.......................................................................................904 Removal And Installation......................................................................907 Disassembly And Assembly......................................................................908 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)......................................................909 AIR CONDITIONING SYSTEM FLOW......................................................................912 Description...................................................................................912 Chart.........................................................................................913 Components....................................................................................914 Safety Equipment..............................................................................917 REGULAR MAINTENANCE...............................................................................919 Filters.......................................................................................919 Compressor Drive Belt Adjustment..............................................................920 Compressor Drive Belt Replacement.............................................................921 Condenser.....................................................................................921 Air Conditioning Lubrication..................................................................921 Air Conditioning Service Chart................................................................922 Evaporator / Heater Coil......................................................................923 TROUBLESHOOTING...................................................................................925 Blower Motor Does Not Operate.................................................................925 Blower Motor Operates Normally, But Air Flow Is Insufficient..................................925 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....................925 The Compressor Does Not Operate At All, Or Operates Improperly................................925 Gauge Pressure Related Troubleshooting........................................................926 Troubleshooting Tree..........................................................................928 Temperature / Pressure Chart..................................................................932 Poor A/C Performance..........................................................................933 HVAC Repair And Leaks.........................................................................934 Electrical System.............................................................................935 Engine Coolant Bypassing The Heater Valve.....................................................942 Heater Valve Not Opening Or Closing...........................................................943 SYSTEM CHARGING AND RECLAMATION...................................................................945 Refrigerant Identification....................................................................945 Reclamation And Charging With Recovery / Charging Unit........................................946 Charging With A Manifold Gauge Set............................................................948 COMPRESSOR........................................................................................951 Removal And Installation......................................................................951 Oil...........................................................................................953 Oil Check.....................................................................................953 Clutch Disassembly And Assembly...............................................................955 CONDENSER.........................................................................................959 Removal And Installation......................................................................959 RECEIVER / DRIER..................................................................................961 Receiver / Drier Removal And Installation.....................................................961 Pressure Relief Valve Removal And Installation................................................962 Pressure Switch Removal And Installation......................................................963 Schraeder® Valve Removal And Installation.....................................................964 EVAPORATOR / HEATER UNIT..........................................................................965 Removal And Installation......................................................................965 THERMOSTAT........................................................................................967 Description...................................................................................967 Removal And Installation......................................................................968 EXPANSION VALVE...................................................................................969 Removal And Installation......................................................................969 EVAPORATOR COIL...................................................................................971 Removal And Installation......................................................................971 HEATER COIL.......................................................................................973 Removal And Installation With A/C.............................................................973 Removal And Installation Without A/C..........................................................975 BLOWER FAN........................................................................................977 Removal And Installation......................................................................977 Disassembly And Assembly......................................................................978 Connector Identification......................................................................980 HEATER VALVE......................................................................................981 Removal And Installation......................................................................981 Disassembly And Assembly......................................................................982 SPECIFICATIONS........................................................................................983 (T190) LOADER SPECIFICATIONS......................................................................985 Machine Dimensions............................................................................985 Performance...................................................................................986 Engine........................................................................................986 Drive System..................................................................................986 Controls......................................................................................987 Hydraulic System..............................................................................987 Electrical....................................................................................988 Capacities....................................................................................988 Tracks........................................................................................988 Ground Pressure...............................................................................988 TORQUE SPECIFICATIONS FOR BOLTS...................................................................989 Torque For General SAE Bolts..................................................................989 Torque For General Metric Bolts...............................................................990 HYDRAULIC CONNECTION SPECIFICATIONS...............................................................991 O-ring Face Seal Connection...................................................................991 Straight Thread O-ring Fitting................................................................992 Tubelines And Hoses...........................................................................992 Flare Fitting.................................................................................993 Port Seal Fitting.............................................................................994 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS......................................................995 Specifications................................................................................995 CONVERSIONS.......................................................................................997 Decimal And Millimeter Equivalent Chart.......................................................997 U.S. To Metric Conversion Chart...............................................................997 ALPHABETICAL INDEX....................................................................................999
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