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Bobcat T190 Turbo T190 Turbo High Flow G Series Loader Service Manual 6901117 – PDF DOWNLOAD
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Bobcat T190 Turbo T190 Turbo High Flow G Series Loader Service Manual 6901117 – PDF DOWNLOAD
(S/N 519311001 & Above)
(S/N 519411001 & Above)
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Description
Bobcat T190 Turbo T190 Turbo High Flow G Series Loader Service Manual 6901117 – PDF DOWNLOAD
FILE DETAILS:
Bobcat T190 Turbo T190 Turbo High Flow G Series Loader Service Manual 6901117 – PDF DOWNLOAD
Language : English
Pages : 871
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T190 Turbo T190 Turbo High Flow G Series Loader Service Manual 6901117 – PDF DOWNLOAD
(S/N 519311001 & Above)
(S/N 519411001 & 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 Turbo T190 Turbo High Flow G Series Loader Service Manual 6901117 – PDF DOWNLOAD
MAINTENANCE SAFETY............................................................................... 3 ALPHABETICAL INDEX............................................................................... 5 CONTENTS......................................................................................... 7 FOREWORD..................................................................................... 8 SAFETY INSTRUCTIONS.......................................................................... 11 Fire Prevention.......................................................................... 13 SERIAL NUMBER LOCATION....................................................................... 15 Loader Serial Number..................................................................... 15 Engine Serial Number..................................................................... 15 DELIVERY REPORT.............................................................................. 15 BOBCAT LOADER IDENTIFICATION................................................................. 16 SAFETY & MAINTENANCE............................................................................. 17 LIFTING AND BLOCKING THE LOADER.............................................................. 19 Procedure................................................................................ 19 Single Point Lift........................................................................ 20 LIFT ARM SUPPORT DEVICE...................................................................... 21 Installing Lift Arm Support Device....................................................... 21 Removing Lift Arm Support Device......................................................... 22 OPERATOR CAB................................................................................. 23 Description.............................................................................. 23 Raising The Operator Cab................................................................. 23 Lowering The Operator Cab................................................................ 24 Emergency Exit........................................................................... 25 TRANSPORTING THE BOBCAT LOADER............................................................... 27 Procedure................................................................................ 27 TOWING THE LOADER (S/N 519313197 & BELOW).................................................... 29 Procedure................................................................................ 29 TOWING THE LOADER (S/N 519313198 & ABOVE).................................................... 31 Procedure................................................................................ 31 REMOTE START................................................................................. 33 Procedure................................................................................ 33 SERVICE SCHEDULE............................................................................. 35 Chart.................................................................................... 35 AIR CLEANER SERVICE.......................................................................... 37 Replacing Filter Element................................................................. 37 ENGINE COOLING SYSTEM........................................................................ 39 Cleaning The Cooling System.............................................................. 39 Checking The Coolant Level............................................................... 40 Replacing the Coolant.................................................................... 40 FUEL SYSTEM.................................................................................. 43 Fuel Specifications...................................................................... 43 Filling The Fuel Tank.................................................................... 43 Fuel Filter.............................................................................. 44 Removing Air From The Fuel System........................................................ 44 ENGINE LUBRICATION SYSTEM.................................................................... 45 Checking Engine Oil...................................................................... 45 Oil Chart................................................................................ 45 Replacing Oil And Filter................................................................. 45 HYDRAULIC/HYDROSTATIC SYSTEM................................................................. 47 Checking And Adding Fluid................................................................ 47 Replacing Hydraulic/Hydrostatic Filter................................................... 47 Replacing Hydraulic Fluid................................................................ 48 Breather Cap............................................................................. 49 FAN GEARBOX.................................................................................. 51 Checking And Maintaining................................................................. 51 BOB-TACH..................................................................................... 53 Inspection And Maintenance............................................................... 53 POWER BOB-TACH (OPTION)...................................................................... 55 Inspection And Maintenance............................................................... 55 LUBRICATION OF THE BOBCAT LOADER............................................................. 57 Procedure................................................................................ 57 SPARK ARRESTOR MUFFLER....................................................................... 61 Cleaning Procedure....................................................................... 61 HYDRAULIC SYSTEM................................................................................. 63 HYDRAULIC/HYDROSTATIC SCHEMATICS............................................................. 67 HYDRAULIC SYSTEM INFORMATION................................................................. 87 Troubleshooting Chart.................................................................... 91 Tighten Procedures....................................................................... 92 CYLINDER (LIFT).............................................................................. 93 Checking................................................................................. 93 Removal And Installation................................................................. 94 Identification........................................................................... 96 Disassembly.............................................................................. 97 Assembly................................................................................. 98 CYLINDER (TILT)..............................................................................101 Checking.................................................................................101 Removal And Installation.................................................................102 Base End Pivot Pin Replacement...........................................................103 Rod End Pivot Pin Bushing And Seal Replacement...........................................104 Parts Identification.....................................................................105 Disassembly..............................................................................106 Assembly.................................................................................107 CYLINDER (POWER BOB-TACH)....................................................................111 Checking.................................................................................111 Removal And Installation.................................................................112 Identification...........................................................................113 Disassembly..............................................................................114 Assembly.................................................................................115 MAIN RELIEF VALVE............................................................................119 Checking.................................................................................119 Adjustment...............................................................................120 Removal and Installation.................................................................120 HYDRAULIC CONTROL VALVE (FOOT CONTROL).......................................................121 Removal And Installation.................................................................121 BICS™ Valve Removal And Installation.....................................................126 BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly...........................127 BICS™ Valve, Check Valve Disassembly And Assembly........................................128 BICS™ Valve Lock Valve Disassembly And Assembly..........................................129 BICS™ Valve Solenoid Disassembly And Assembly............................................130 BICS™ Valve Solenoid Testing.............................................................131 Identification Chart.....................................................................132 Load Check Valve.........................................................................133 Main Relief Valve........................................................................134 Port Relief Valve........................................................................135 Anti-Cavitation Valve/Port Relief Valve..................................................136 Anti-Cavitation Valve....................................................................137 Rubber Boot..............................................................................138 Lift And Tilt Lock Block.................................................................138 Lift Spool and Detent....................................................................139 Tilt Spool Removal And Installation......................................................148 Auxiliary Spool Removal And Installation.................................................150 Auxiliary Electric Solenoid Disassembly..................................................151 Port-Auxiliary Section Disassembly.......................................................152 Cleaning And Inspection..................................................................152 HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS)......................................153 Removal And Installation.................................................................153 BICS™ Valve Removal And Installation.....................................................157 BICS™ Valve, Lift Arm By-Pass Orifice Dissembly And Assembly.............................158 BICS™ Valve, Check Valve Dissembly And Assembly..........................................159 BICS™ Valve Lock Valve Dissembly And Assembly............................................160 BICS™ Valve Solenoid Dissembly And Assembly..............................................161 BICS™ Valve Solenoid Testing.............................................................162 Actuator Removal And Installation........................................................163 Identification Chart (Hand Control)......................................................164 Identification Chart (ACS)...............................................................165 Lift Base End Restrictor.................................................................166 Load Check Valve.........................................................................166 Main Relief Valve........................................................................167 Port Relief Valve........................................................................168 Anti-Cavitation Valve/Port Relief Valve..................................................169 Anti-Cavitation Valve....................................................................170 Lift Spool Removal And Installation......................................................171 Tilt Spool Removal And Installation......................................................172 Lift and Tilt Spool Disassembly And Assembly.............................................173 Auxiliary Spool Removal And Installation.................................................174 Auxiliary Electric Solenoid Disassembly..................................................175 Port-Auxiliary Section Disassembly.......................................................176 Cleaning And Inspection..................................................................176 LIFT ARM BY-PASS CONTROL VALVE...............................................................177 Inspecting...............................................................................177 Removal And Installation.................................................................177 Disassembly And Assembly.................................................................178 HYDRAULIC PUMP...............................................................................179 Check The Output Of The Hydraulic Pump Without Power Bob-Tach............................179 Check The Output Of The Hydraulic Pump With Power Bob-Tach...............................181 Removal And Installation.................................................................183 Identification...........................................................................185 Disassembly And Assembly.................................................................186 HYDRAULIC PUMP (HIGH FLOW)...................................................................191 Check The Output Of The Hydraulic Pump Without Power Bob-Tach (S/N 519315699 & Below)....191 Check The Output Of The Hydraulic Pump With Power Bob-Tach (S/N 519315699 & Below).......193 Check The Output Of The Hydraulic Pump (Standard)(S/N 519315700 & Above).................195 Check The Output Of The Hydraulic Pump (High Flow)(S/N 519315700 & Above)................197 Removal And Installation.................................................................199 Identification...........................................................................201 Disassembly And Assembly.................................................................202 HYDRAULIC FILTER HOUSING.....................................................................211 Removal And Installation.................................................................211 HYDRAULIC FLUID RESERVOIR....................................................................213 Removal And Installation.................................................................213 BUCKET POSITION VALVE........................................................................217 Solenoid Removal And Installation........................................................217 Solenoid Testing.........................................................................218 Removal And Installation.................................................................218 Disassembly And Assembly.................................................................220 SELECT VALVE (S/N 519315699 & BELOW).........................................................223 Checking The High Flow Pump Relief Valve.................................................223 Removal And Installation.................................................................225 Disassembly And Assembly.................................................................228 Solenoid Testing.........................................................................233 HIGH FLOW VALVE (S/N 519315700 & ABOVE)......................................................235 Checking The High Flow Relief Valve......................................................235 High Flow Relief Valve Adjustment Procedure..............................................237 Removal And Installation.................................................................238 Disassembly And Assembly.................................................................240 Solenoid Testing.........................................................................242 REAR AUXILIARY DIVERTER VALVE (DUAL SHUTTLE) (S/N 519315699 & BELOW).........................243 Removal And Installation.................................................................243 Disassembly And Assembly.................................................................248 Solenoid Testing.........................................................................251 Inspection...............................................................................251 REAR AUXILIARY DIVERTER VALVE (S/N 519315700 & Above)........................................253 Removal And Installation.................................................................253 Disassembly And Assembly.................................................................256 Solenoid Testing.........................................................................261 Inspection...............................................................................261 POWER BOB-TACH BLOCK (S/N 519315202 & below).................................................263 Removal And Installation.................................................................263 Disassembly And Assembly.................................................................265 POWER BOB-TACH BLOCK (S/N 519315203 & Above).................................................273 Removal And Installation.................................................................273 Disassembly And Assembly.................................................................275 FRONT AUXILIARY PRESSURE RELIEF BLOCK........................................................279 Removal And Installation (519312091 & Below).............................................279 Disassembly And Assembly (519312091 & Below).............................................280 Solenoid Testing.........................................................................281 Solenoid Inspection......................................................................281 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK......................................................283 Removal and Installation (519312092 & Above).............................................283 Disassembly And Assembly (519312092 & Above).............................................283 HYDROSTATIC SYSTEM...............................................................................285 HYDROSTATIC SYSTEM INFORMATION...............................................................287 Troubleshooting Chart....................................................................287 Replenishing Valve Function..............................................................288 HYDROSTATIC MOTOR............................................................................289 Replacing the Motor Oil (Motor S/N 428302 & Above).......................................289 Removal And Installation.................................................................290 Parts Identification (Motor S/N 428301 & Below)..........................................292 Parts Identification (Motor S/N 428302 & Above)..........................................294 Disassembly..............................................................................296 Inspection...............................................................................304 Assembly.................................................................................306 CHARGE PRESSURE..............................................................................317 Sender Removal And Installation..........................................................317 Checking Charge Pressure.................................................................317 Adjusting................................................................................318 HYDROSTATIC PUMP.............................................................................319 Replenishing/High Pressure Relief Valve..................................................319 Removal And Installation.................................................................319 Parts Identification (Right Half)........................................................322 Parts Identification (Left Half).........................................................324 Hydraulic Pump Removal And Installation..................................................326 Pump Separation..........................................................................326 Disassembly..............................................................................327 Assembly.................................................................................333 DRIVE BELT...................................................................................341 Shield Removal And Installation..........................................................341 Adjusting................................................................................341 Drive Belt Replacement...................................................................343 Tensioner Pulley Removal And Installation................................................344 Tensioner Pulley Parts Identification....................................................345 Tensioner Pulley Disassembly.............................................................346 Tensioner Pulley Assembly................................................................347 OIL COOLER...................................................................................349 Removal and Installation.................................................................349 DRIVE SYSTEM.....................................................................................351 BRAKE........................................................................................353 Switch Operated Parking Brake............................................................353 Brake Engaged (Dragging) Test (S/N 519313197 & Below)....................................353 Block Removal And Installation (S/N 519313197 & Below)...................................361 Block Disassembly And Assembly (S/N 519313197 & Below)...................................363 Traction Lock By-Pass Knob (S/N 519313197 & Below).......................................364 BRAKE (S/N 519313198 AND ABOVE)..............................................................365 Pressure Relief Valve Test...............................................................365 Left Motor Brake Test....................................................................367 Block Removal And Installation...........................................................369 Block Disassembly And Assembly...........................................................370 DRIVE COMPONENTS.............................................................................373 Track Tension............................................................................373 Track Tension Adjusting..................................................................373 Track Removal And Installation...........................................................376 Track Idler (Front) Removal And Installation.............................................379 Track Idler (Front) Parts Identification (S/N 519313368 & Below).........................381 Track Idler (Front) Disassembly (S/N 519313368 & Below)..................................382 Track Idler (Front) Assembly.............................................................383 Track Idler (Rear) Removal And Installation..............................................385 Track Idler (Rear) Parts Identification (S/N 519313368 & Below)..........................386 Track Idler (Rear) Disassembly (S/N 519313368 & Below)...................................387 Track Idler (Rear) Assembly (S/N 519313368 & Below)......................................388 Track Roller Removal And Installation....................................................389 Track Roller Parts Identification (S/N 519313368 & Below)................................390 Track Roller Disassembly (S/N 519313368 & Below).........................................391 Track Roller Assembly....................................................................392 Track Idler (Front) Parts Identification (S/N 519313369 & Above).........................394 Track Idler (Front) Disassembly (S/N 519313369 & Above)..................................395 Track Idler (Front) Assembly (S/N 519313369 & Above).....................................396 Track Idler (Rear) End Play Specifications (S/N 519313369 & Above).......................399 Track Idler (Rear) Parts Identification (S/N 519313369 & Above)..........................399 Track Idler (Rear) Removal And Installation (S/N 519313369 & Above)......................399 Track Idler (Rear) Disassembly (S/N 519313369 & Above)...................................400 Track Roller Assembly End Play Specifications (S/N 519313369 & Above)....................403 Track Roller Parts Identification(S/N 519313369 & Above).................................403 Track Roller Removal And Installation (S/N 519313369 & Above)............................403 Track Roller Disassembly (S/N 519313369 & Above).........................................404 Track Roller Assembly (S/N 519313369 & Above)............................................405 Track Housing Removal And Installation...................................................407 Track Damage Identification..............................................................408 MAIN FRAME.......................................................................................421 SEAT BAR.....................................................................................423 Removal And Installation.................................................................423 Assembling Components....................................................................425 Compression Spring Disassembly And Assembly..............................................427 OPERATOR CAB.................................................................................429 Gas Cylinder Removal And Installation....................................................429 Gas Cylinder Disassembly.................................................................431 Removal And Installation.................................................................432 OPERATOR SEAT................................................................................435 Removal And Installation.................................................................435 Seat Belt Removal And Installation.......................................................435 OPERATOR SEAT (SUSPENSION)...................................................................437 Removal And Installation.................................................................437 Slide Rail Removal And Installation......................................................438 Cushion Removal And Installation.........................................................438 Back Removal And Installation............................................................439 Shock Removal And Installation...........................................................440 3-Point Seat Belt Removal And Installation...............................................441 BOB-TACH.....................................................................................443 Removal And Installation.................................................................443 Bob-Tach Lever And Wedge.................................................................444 Pivot Pin Bushing And Seal Replacement...................................................446 POWER BOB-TACH...............................................................................447 Removal And Installation.................................................................447 Power Bob-Tach Lever And Wedge...........................................................448 Pivot Pin Bushing And Seal Replacement...................................................450 LIFT ARM.....................................................................................451 Removal And Installation.................................................................451 Link Removal And Installation............................................................455 Stabilizer Bar Removal And Installation..................................................456 REAR GRILL...................................................................................457 Gas Cylinder Removal And Installation (Earlier Models Only)..............................457 Removal And Installation (Earlier Models)................................................458 Removal And Installation (Later Models)..................................................459 REAR DOOR....................................................................................461 Removal And Installation.................................................................461 Door Latch And Catch Adjustment (519311949 & Below)......................................462 Door Latch Removal And Installation (519311949 & Below)..................................463 Striker Removal and Installation (S/N 519311950 & Above).................................464 Striker Disassembly and Assembly (S/N 512261536 & Above).................................464 Adjusting The Striker (S/N 519311950 & Above)............................................464 Latch Removal and Installation (S/N 519311950 & Above)...................................465 FUEL TANK....................................................................................467 Removal And Installation.................................................................467 Fuel Level Sender........................................................................468 Fuel Fill Screen.........................................................................468 Fuel Pickup Screen.......................................................................469 CONTROL PEDALS...............................................................................471 Removal And Installation.................................................................471 Pedal Adjustment.........................................................................471 Crossbar Linkage Removal And Installation................................................472 Lift Foot Pedal Linkage Removal And Installation.........................................473 Tilt Foot Pedal Linkage Removal And Installation.........................................474 CONTROL PEDALS (ACS).........................................................................475 Foot Sensor Removal And Installation.....................................................475 Foot Pedal Removal And Installation......................................................476 Foot Pedal Linkage Disassembly And Assembly..............................................477 CONTROL PANEL................................................................................479 Removal and Installation.................................................................479 Shock Removal And Installation...........................................................482 Shaft Removal And Installation...........................................................482 Shaft Disassembly And Assembly...........................................................482 Linkage Removal And Installation.........................................................483 Linkage Adjustment.......................................................................486 Linkage Neutral Adjustment...............................................................490 CONTROL HANDLE...............................................................................493 Control Lever Removal And Installation...................................................493 Control Lever Boot.......................................................................493 CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) ADVANCED HAND CONTROL.........................495 Components Identification................................................................495 Handle Sensor Removal And Installation...................................................496 Control Handle Removal and Installation..................................................499 Control Handle Disassembly and Assembly..................................................500 Control Lever Removal and Installation...................................................500 Control Lever Boot.......................................................................501 CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL..................503 Components Identification................................................................503 Handle Sensor Removal And Installation...................................................504 Control Handle Removal and Installation..................................................507 Control Handle Disassembly and Assembly..................................................508 Control Lever Removal and Installation...................................................508 Control Lever Boot.......................................................................509 ELECTRICAL SYSTEM................................................................................511 ELECTRICAL SCHEMATICS........................................................................515 ELECTRICAL SYSTEM INFORMATION................................................................524 Wiring Schematics........................................................................524 Troubleshooting Chart....................................................................526 Description..............................................................................527 Fuse Location............................................................................528 Relay Switch Location....................................................................528 Solenoid Test............................................................................529 BATTERY......................................................................................530 Removal And Installation.................................................................530 Servicing................................................................................531 Using A Booster Battery (Jump Starting)..................................................532 ALTERNATOR (90 AMP)..........................................................................534 Adjusting The Alternator Belt............................................................534 Alternator Identification................................................................534 Charging System Check....................................................................535 Alternator Voltage Test..................................................................537 Low Voltage Test.........................................................................537 High Voltage Test........................................................................538 Removal And Installation.................................................................539 Rectifier Continuity (Diode) Test........................................................540 Alternator Regulator Test................................................................541 Disassembly..............................................................................541 Stator Continuity Test...................................................................542 Stator Ground Test.......................................................................542 Rotor Continuity Test....................................................................542 Rotor Ground Test........................................................................542 Assembly.................................................................................543 STARTER (NIPPONDENSO)........................................................................544 Checking.................................................................................544 Removal And Installation.................................................................544 Parts Identification.....................................................................546 Disassembly..............................................................................547 Inspection And Repair....................................................................552 No Load Test.............................................................................556 Assembly.................................................................................556 STARTER (VALEO)..............................................................................564 Checking.................................................................................564 Removal And Installation.................................................................565 Parts Identification.....................................................................566 Disassembly and Assembly.................................................................567 Inspection And Repair....................................................................570 No Load Test.............................................................................572 INSTRUMENT PANEL.............................................................................574 Left Panel (Standard)....................................................................574 Right Panel-Standard Instrument Panel (With Key Switch)..................................575 Right Panel - (Deluxe) (With Keyless Start)..............................................576 Right Panel Setup Display Options (Deluxe)...............................................578 Option and Field Accessory Panels........................................................580 Removal And Installation.................................................................581 Front Accessory Panel Removal And Installation...........................................582 LIGHTS.......................................................................................584 Front Removal And Installation...........................................................584 Rear Removal And Installation............................................................585 BOBCAT CONTROLLER............................................................................586 Identification Chart (S/N 519313304 & Below).............................................586 Identification Chart (S/N 519313305 & Above).............................................587 Removal And Installation.................................................................589 DIAGNOSTIC SERVICE CODES.....................................................................592 Display..................................................................................592 Number Codes List........................................................................593 BICS™ SYSTEM.................................................................................598 Inspecting The BICS™ Controller (Engine STOPPED - Key ON)................................598 Inspecting Deactivation Of The Auxiliary Hydraulics......................................598 System (Engine STOPPED - Key ON).........................................................598 Inspecting The Seat Bar Sensor (Engine RUNNING)..........................................598 Inspecting The Traction Lock (Engine RUNNING)............................................598 Inspecting The Lift Arm By-Pass Control..................................................599 Additional Inspection For Loaders With Advanced Hand Controls (AHC)......................599 Troubleshooting Chart....................................................................600 Troubleshooting Guide....................................................................601 SEAT BAR SENSOR..............................................................................602 Troubleshooting Chart....................................................................602 Test.....................................................................................603 Removal And Installation.................................................................604 BICS™ Circuit Test.......................................................................605 TRACTION LOCK................................................................................608 Troubleshooting Chart....................................................................608 Description Of The Control System........................................................609 Inspecting The Control System............................................................609 ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND CONTROL..........................................610 Components Identification................................................................610 Troubleshooting Guide....................................................................611 Controller, Connector And Wire Identification............................................612 ACS Controller Removal And Installation..................................................613 Handle Sensor Connector..................................................................614 Switch Handle Removal....................................................................615 Switch Handle Installation...............................................................617 Actuators Disassembly and Assembly.......................................................620 ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND/FOOT CONTROL...................................622 Components Identification................................................................622 Troubleshooting Guide....................................................................624 Controller, Connector And Wire Identification............................................625 ACS Controller Removal And Installation..................................................626 Handle Sensor Connector..................................................................627 Switch Handle Removal....................................................................628 Switch Handle Installation...............................................................630 Actuators Disassembly and Assembly.......................................................633 Handle Lock Solenoid Removal And Installation............................................634 Handle Lock Solenoid Disassembly And Assembly............................................635 Handle Lock Solenoid Connector...........................................................635 Calibration Procedure....................................................................637 Foot Sensor Disassembly And Assembly.....................................................641 Foot Sensor Connector....................................................................641 Foot Lock Solenoid Removal And Installation..............................................642 Foot Lock Solenoid Connector.............................................................643 ELECTRICAL/HYDRAULIC CONTROLS REFERENCE......................................................644 Controls Identification Chart............................................................644 FLYWHEEL RPM SENSOR..........................................................................648 Adjustment...............................................................................648 ENGINE SERVICE...................................................................................650 TROUBLESHOOTING..............................................................................652 Chart....................................................................................652 ENGINE SPEED CONTROL.........................................................................654 Removal And Installation.................................................................654 Disassembly..............................................................................654 MUFFLER......................................................................................656 Removal And Installation.................................................................656 AIR CLEANER..................................................................................658 Removal And Installation.................................................................658 RADIATOR (S/N 519314343 & BELOW).............................................................660 Removal And Installation.................................................................660 RADIATOR (S/N 519314344 & ABOVE).............................................................664 Removal And Installation.................................................................664 COOLING FAN..................................................................................668 Drive Tension Pulley Removal And Installation............................................668 Gearbox/Blower Housing Removal And Installation..........................................669 Blower Housing Grill Removal And Installation............................................671 Blower Disassembly And Assembly..........................................................671 Gearbox Parts Identification.............................................................673 Gearbox Disassembly......................................................................674 Gearbox Assembly.........................................................................679 Gearbox Checking Backlash................................................................684 ENGINE COMPONENTS AND TESTING................................................................688 Compression Checking.....................................................................688 Glow Plugs Checking......................................................................689 Glow Plugs Removal And Installation......................................................689 Fuel Shut-Off Solenoid, Checking.........................................................690 Fuel Shut-Off Solenoid, Adjusting........................................................690 Fuel Shut-Off Solenoid Removal And Installation..........................................691 Checking.................................................................................692 Fuel Injection Pump Removal And Installation.............................................693 ENGINE COMPONENTS AND TESTING (CONT’D).......................................................696 Timing The Injection Pump................................................................696 Fuel Injector Removal And Installation...................................................698 Fuel Injector Checking...................................................................700 Fuel Injector Disassembly................................................................700 Fuel Injector Assembly...................................................................701 Valve Clearance Adjustment...............................................................701 Rocker Arm And Shaft Checking............................................................702 Valve Timing, Checking...................................................................702 ENGINE.......................................................................................704 Removal And Installation.................................................................704 Engine Mount Replacement.................................................................711 FLYWHEEL AND HOUSING.........................................................................714 Flywheel Removal And Installation........................................................714 Ring Gear Removal And Installation.......................................................714 Housing Removal And Installation.........................................................715 RECONDITIONING THE ENGINE-V2003T-EB (TURBO)..................................................718 Cylinder Head Removal And Installation...................................................718 Cylinder Head Disassembly And Assembly...................................................719 Cylinder Head Servicing..................................................................720 Cylinder Head Top Clearance..............................................................720 Checking The Valve Guide.................................................................721 Reconditioning The Valve And Valve Seat..................................................722 Valve Spring.............................................................................723 Rocker Arm And Shaft Checking............................................................723 Timing Gearcase Cover Removal And Installation...........................................724 Idler Gear And Camshaft Removal And Installation.........................................726 Servicing The Camshaft...................................................................727 Servicing The Idle Gear And Shaft........................................................728 Timing Gears Checking Backlash...........................................................729 Fuel Camshaft Removal And Installation...................................................730 Fuel Camshaft Governor...................................................................730 Crankshaft Gear Removal And Installation.................................................731 Oil Pump Removal And Installation........................................................731 Oil Pump Service.........................................................................731 Checking Engine Oil Pressure.............................................................732 Relief Valve.............................................................................733 Piston And Connecting Rod Removal And Installation.......................................733 Servicing The Piston And Connecting Rod..................................................735 Connecting Rod Alignment.................................................................736 Crankshaft And Bearings Removal And Installation.........................................737 Servicing The Crankshaft And Bearings....................................................738 Checking The Cylinder Bore...............................................................742 Water Pump Disassembly And Assembly......................................................742 TURBOCHARGER.................................................................................744 Troubleshooting..........................................................................744 Description..............................................................................745 Removal And Installation.................................................................745 HEATING, VENTILATION, AIR CONDITIONING...........................................................748 AIR CONDITIONING SYSTEM FLOW.................................................................751 Principals...............................................................................751 Chart....................................................................................752 COMPONENTS...................................................................................754 Identification...........................................................................754 SAFETY.......................................................................................758 Safety Equipment.........................................................................758 REGULAR MAINTENANCE..........................................................................760 Filter Elements Removal And Installation (Cont'd)........................................761 Compressor Drive Belt Inspection.........................................................761 Cleaning The Condenser...................................................................762 Filter Elements Removal And Installation.................................................760 BASIC TROUBLESHOOTING........................................................................764 Poor A/C Performance.....................................................................764 Cleaning The A/C Evaporator Coil & Heater Coil...........................................765 Compressor Drive Belt Inspection.........................................................767 Checking The Electrical System...........................................................768 Engine Coolant By-Passing The Heater Valve...............................................775 Heater Valve Not Opening Or Closing......................................................776 GENERAL AIR CONDITIONING SERVICE GUIDELINES..................................................778 Compressor Oil...........................................................................778 Compressor Oil Check.....................................................................779 Component Replacement And Refrigeration Leaks............................................780 SYSTEM TROUBLESHOOTING CHART.................................................................782 TEMPERATURE/PRESSURE.........................................................................786 Chart....................................................................................786 AIR CONDITIONING SERVICE.....................................................................788 Chart....................................................................................788 SYSTEM CHARGING AND RECLAMATION..............................................................790 Reclamation Procedure....................................................................790 Charging Procedure With A Manifold Gauge Set.............................................793 Charging Procedure.......................................................................794 COMPRESSOR...................................................................................796 Removal And Installation.................................................................796 Compressor Clutch Disassembly............................................................797 CONDENSER....................................................................................802 Removal And Installation.................................................................802 RECEIVER/DRIER...............................................................................804 Removal And Installation.................................................................804 PRESSURE RELIEF VALVE........................................................................806 Removal And Installation.................................................................806 PRESSURE SWITCH..............................................................................808 Removal And Installation.................................................................808 EVAPORATOR/HEATER UNIT.......................................................................810 Removal And Installation.................................................................810 Disassembly And Assembly.................................................................811 THERMOSTAT...................................................................................812 Removal And Installation.................................................................812 EXPANSION VALVE..............................................................................814 Removal And Installation.................................................................814 EVAPORATOR...................................................................................816 Removal And Installation.................................................................816 HEATER COIL..................................................................................818 Removal And Installation With A/C........................................................818 Removal And Installation Without A/C.....................................................819 HEATER/AC FAN................................................................................820 Removal And Installation.................................................................820 Disassembly And Assembly.................................................................821 Wire Connector Removal and Installation..................................................823 HEATER VALVE.................................................................................826 Removal and Installation.................................................................826 Disassembly And Assembly.................................................................827 SPECIFICATIONS...................................................................................830 LOADER SPECIFICATIONS........................................................................832 Loader Dimensions........................................................................832 Performance..............................................................................833 Controls.................................................................................833 Engine...................................................................................833 Hydraulic System.........................................................................834 Electrical...............................................................................834 Drive System.............................................................................835 Capacities...............................................................................835 Tracks...................................................................................835 Ground Pressure..........................................................................835 ENGINE SPECIFICATIONS - KUBOTA V2003T-EB (TURBO).............................................836 Fuel Injection Nozzles...................................................................836 Fuel Injection Pump......................................................................836 Cylinder Head............................................................................836 Valves...................................................................................836 Valve Springs............................................................................837 Valve Timing.............................................................................837 Rocker Arms..............................................................................837 Camshaft.................................................................................837 Tappet...................................................................................837 Cylinder Liner...........................................................................838 Piston Rings.............................................................................838 Pistons..................................................................................838 Connecting Rod...........................................................................838 Oil Pump.................................................................................838 Crankshaft...............................................................................839 Timing Gear..............................................................................839 Thermostat...............................................................................839 Crankshaft Re-Grind Data.................................................................840 TORQUE SPECIFICATIONS FOR BOLTS..............................................................842 Torque For General SAE Bolts.............................................................842 Torque For General Metric Bolts..........................................................843 HYDRAULIC CONNECTION SPECIFICATIONS..........................................................844 O-ring Face Seal Connection..............................................................844 Straight Thread O-ring Fitting...........................................................845 Tubelines And Hoses......................................................................845 Flare Fitting............................................................................845 O-ring Flare Fitting.....................................................................846 Port Seal Fitting........................................................................848 HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS...................................................850 Specifications...........................................................................850 CONVERSIONS..................................................................................852 Decimal And Millimeter Equivalents.......................................................852 U.S. To Metric Conversion................................................................852 SMR..............................................................................................854 Revision No: T190-1..........................................................................854 Revision No: T190-2..........................................................................856 Revision No: T190-3..........................................................................858 Revision No: T190-4..........................................................................860 Revision No: T190-5..........................................................................862 Revision No: T190-6..........................................................................864 Revision No: T190-7..........................................................................868 Revision No: T190-8..........................................................................870
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