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Bobcat T190 Turbo T190 Turbo High Flow G Series Loader Service Manual 6902734 (10-09) – PDF DOWNLOAD
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Bobcat T190 Turbo T190 Turbo High Flow G Series Loader Service Manual 6902734 (10-09) – PDF DOWNLOAD
S/N 527011001 & Above
S/N 527911001 & Above
S/N 527711001 & Above
S/N 527811001 & Above
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Description
Bobcat T190 Turbo T190 Turbo High Flow G Series Loader Service Manual 6902734 (10-09) – PDF DOWNLOAD
FILE DETAILS:
Bobcat T190 Turbo T190 Turbo High Flow G Series Loader Service Manual 6902734 (10-09) – PDF DOWNLOAD
Language : English
Pages : 963
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T190 Turbo T190 Turbo High Flow G Series Loader Service Manual 6902734 (10-09) – PDF DOWNLOAD
S/N 527011001 & Above
S/N 527911001 & Above
S/N 527711001 & Above
S/N 527811001 & 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 6902734 (10-09) – PDF DOWNLOAD
MAINTENANCE SAFETY.............................................................................. 3 ALPHABETICAL INDEX.............................................................................. 5 CONTENTS........................................................................................ 7 FOREWORD.................................................................................... 8 SAFETY INSTRUCTIONS......................................................................... 11 FIRE PREVENTION............................................................................. 13 Maintenance............................................................................. 13 Operation............................................................................... 13 Electrical.............................................................................. 13 Hydraulic System........................................................................ 13 Fueling................................................................................. 13 Starting................................................................................ 13 Spark Arrestor Exhaust System........................................................... 13 Welding And Grinding.................................................................... 14 Fire Extinguishers...................................................................... 14 SERIAL NUMBER LOCATIONS..................................................................... 15 Loader Serial Number.................................................................... 15 Engine Serial Number.................................................................... 15 DELIVERY REPORT............................................................................. 16 BOBCAT LOADER IDENTIFICATION................................................................ 17 SAFETY & MAINTENANCE............................................................................ 19 LIFTING AND BLOCKING THE LOADER............................................................. 21 Procedure............................................................................... 21 Single Point Lift....................................................................... 22 LIFT ARM SUPPORT DEVICE..................................................................... 23 Installing Lift Arm Support Device...................................................... 23 Removing Lift Arm Support Device........................................................ 24 OPERATOR CAB................................................................................ 25 Description............................................................................. 25 Raising The Operator Cab................................................................ 25 Lowering The Operator Cab............................................................... 26 Emergency Exit.......................................................................... 27 TRANSPORTING THE BOBCAT LOADER.............................................................. 29 Procedure............................................................................... 29 TOWING THE LOADER........................................................................... 31 Procedure............................................................................... 31 REMOTE START................................................................................ 33 Procedure............................................................................... 33 SERVICE SCHEDULE............................................................................ 37 Chart................................................................................... 37 AIR CLEANER SERVICE......................................................................... 39 Replacing Filter Element................................................................ 39 ENGINE COOLING SYSTEM....................................................................... 41 Cleaning The Cooling System............................................................. 41 Checking The Coolant Level.............................................................. 42 Replacing the Coolant................................................................... 42 FUEL SYSTEM................................................................................. 45 Fuel Specifications..................................................................... 45 Filling The Fuel Tank................................................................... 45 Fuel Filter............................................................................. 46 Removing Air From The Fuel System....................................................... 46 ENGINE LUBRICATION SYSTEM................................................................... 47 Checking Engine Oil..................................................................... 47 Oil Chart............................................................................... 47 Replacing Oil And Filter................................................................ 48 HYDRAULIC/HYDROSTATIC SYSTEM................................................................ 49 Checking And Adding Fluid............................................................... 49 Replacing Hydraulic/Hydrostatic Filter.................................................. 49 Replacing Hydraulic Fluid............................................................... 50 Breather Cap............................................................................ 52 FAN GEARBOX................................................................................. 53 Checking And Maintaining................................................................ 53 BOB-TACH.................................................................................... 55 Inspection And Maintenance.............................................................. 55 POWER BOB-TACH (OPTION)..................................................................... 57 Inspection And Maintenance.............................................................. 57 LUBRICATION OF THE BOBCAT LOADER............................................................ 59 Procedure............................................................................... 59 SPARK ARRESTOR MUFFLER...................................................................... 63 Cleaning Procedure...................................................................... 63 HYDRAULIC SYSTEM................................................................................ 65 HYDRAULIC / HYDROSTATIC SCHEMATICS.......................................................... 71 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................................................................121 HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL)....................................123 Identification..........................................................................123 Removal And Installation................................................................123 BICS Valve Removal And Installation.....................................................127 BICS Valve, Lift Arm Bypass Orifice Disassembly And Assembly............................128 BICS Valve, Check Valve Disassembly And Assembly........................................129 BICS Valve Lock Valve Disassembly And Assembly..........................................130 BICS Valve Solenoid Disassembly And Assembly............................................131 BICS Valve Solenoid Testing.............................................................132 Identification Chart....................................................................133 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 (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)...................153 Identification..........................................................................153 Removal and Installation................................................................153 BICS Valve Removal And Installation.....................................................157 BICS Valve, Lift Arm Bypass Orifice Removal And Installation............................159 BICS Valve, Check Valve Removal And Installation........................................160 BICS Valve Lock Valve Removal And Installation..........................................161 BICS Valve Solenoid Removal And Installation............................................162 BICS Valve Solenoid Testing.............................................................163 Actuator Removal And Installation.......................................................164 Identification Chart (ACS)..............................................................165 Lift Base End Restrictor................................................................165 Load Check Valve........................................................................165 Main Relief Valve.......................................................................167 Port Relief Valve.......................................................................167 Anti-Cavitation Valve/Port Relief Valve.................................................168 Anti-Cavitation Valve...................................................................169 Tilt Spool Removal And Installation.....................................................170 Lift Spool Removal And Installation.....................................................171 Lift and Tilt Spool Disassembly And Assembly............................................171 Auxiliary Spool Removal And Installation................................................172 Auxiliary Electric Solenoid.............................................................173 Port-Auxiliary Section..................................................................175 Cleaning And Inspection.................................................................175 HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL)....................................177 Identification..........................................................................177 Removal And Installation................................................................177 Identification Chart....................................................................183 Mount Bracket Removal and Installation..................................................184 BICS Valve, Lift Load Check Valve Removal And Installation..............................184 Load Check Valve Removal And Installation (Tilt & Auxiliary)............................185 Anti-Cavitation Valve (Lift, Rod End)...................................................186 Port Relief/Anti-Cavitation Valve (Lift, Base End)......................................187 Port Relief/Anti-Cavitation Valve (Tilt, Base End)......................................187 Port Relief/Anti-Cavitation Valve (Tilt, Rod End).......................................188 Port Relief Valve.......................................................................188 Plug Removal............................................................................189 Rubber Boot Removal and Installation....................................................190 End Cap/Spool Lock Block Removal and Installation.......................................191 Lift Spool and Detent Removal and Installation..........................................192 Tilt Spool Removal and Installation.....................................................201 Auxiliary Spool Removal And Installation................................................203 Auxiliary Solenoid Disassembly and Assembly.............................................205 BICS Valve Solenoid Disassembly And Assembly............................................206 BICS Valve, Lock Valve Removal And Installation.........................................207 BICS Valve, Check Valve Removal And Installation........................................209 BICS Valve, Lift Arm Bypass Orifice Disassembly And Assembly............................210 Main Relief Valve.......................................................................210 HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCE CONTROL SYSTEM) (ACS)....................211 Identification..........................................................................211 Removal And Installation................................................................211 Actuator Removal And Installation (Out of Loader).......................................216 Identification Chart (ACS)..............................................................219 Mount Bracket Removal and Installation..................................................220 BICS Valve, Lift Load Check Valve Removal And Installation..............................220 Load Check Valve Removal And Installation (Tilt & Auxiliary)............................221 Anti-Cavitation Valve (Lift, Rod End)...................................................222 Port Relief/Anti-Cavitation Valve (Lift, Base End)......................................223 Port Relief/Anti-Cavitation Valve (Tilt, Base End)......................................223 Port Relief/Anti-Cavitation Valve (Tilt, Rod End).......................................224 Port Relief Valve.......................................................................224 Plug Removal............................................................................225 End Cap Block Removal and Installation..................................................226 Lift Spool Removal and Installation.....................................................227 Tilt Spool Removal and Installation.....................................................231 Auxiliary Spool Removal And Installation................................................233 Auxiliary Solenoid Disassembly and Assembly.............................................234 BICS Valve Solenoid Disassembly And Assembly............................................235 BICS Valve, Lock Valve Removal And Installation.........................................236 BICS Valve, Check Valve Removal And Installation........................................238 BICS Valve, Lift Arm Bypass Orifice Disassembly And Assembly............................239 Main Relief Valve.......................................................................239 LIFT ARM BYPASS CONTROL VALVE...............................................................241 Inspecting..............................................................................241 Removal and Installation................................................................241 Disassembly And Assembly................................................................242 HYDRAULIC PUMP..............................................................................243 Check The Output Of The Hydraulic Pump Without Power Bob-Tach...........................243 Check The Output Of The Hydraulic Pump With Power Bob-Tach..............................245 Removal And Installation................................................................247 Identification..........................................................................249 Disassembly And Assembly................................................................250 HYDRAULIC PUMP (HIGH FLOW)..................................................................255 Check The Output Of The Hydraulic Pump (Standard).......................................255 Check The Output Of The Hydraulic Pump (High Flow)......................................257 Removal And Installation................................................................259 Identification..........................................................................261 Disassembly And Assembly................................................................262 HYDRAULIC PUMP (SJC)........................................................................271 Test The Output Of The Hydraulic Auxiliary Pump.........................................271 Test The Output Of The Hydraulic Charge Pump............................................272 Removal And Installation................................................................274 Identification..........................................................................276 Disassembly And Assembly................................................................277 HYDRAULIC PUMP (HIGH FLOW) (SJC)............................................................285 Test The Output Of The Hydraulic Auxiliary Pump.........................................285 Test The Output Of The Hydraulic Charge Pump............................................286 Test The Output Of The Hydraulic Pump (High Flow).......................................288 Removal And Installation................................................................290 Identification..........................................................................292 Disassembly And Assembly................................................................293 HYDRAULIC/HYDROSTATIC FILTER HOUSING........................................................305 Removal And Installation................................................................305 HYDRAULIC FLUID RESERVOIR...................................................................307 Removal And Installation................................................................307 BUCKET POSITION VALVE.......................................................................311 Solenoid Removal And Installation.......................................................311 Solenoid Testing........................................................................312 Removal And Installation................................................................313 Disassembly And Assembly................................................................315 HIGH FLOW VALVE.............................................................................317 Checking The High Flow Relief Valve.....................................................317 High Flow Relief Valve Adjustment Procedure.............................................319 Removal And Installation................................................................320 Disassembly And Assembly................................................................322 Solenoid Testing........................................................................324 REAR AUXILIARY DIVERTER VALVE...............................................................325 Removal And Installation................................................................325 Disassembly And Assembly................................................................328 Solenoid Testing........................................................................333 Inspection..............................................................................333 POWER BOB-TACH BLOCK........................................................................335 Removal And Installation................................................................335 Disassembly And Assembly................................................................337 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.....................................................341 Removal and Installation................................................................341 Disassembly And Assembly................................................................341 HYDROSTATIC SYSTEM..............................................................................343 HYDROSTATIC SYSTEM INFORMATION..............................................................345 Troubleshooting Chart...................................................................345 Replenishing Valve Function.............................................................346 HYDROSTATIC MOTOR...........................................................................347 Replacing the Motor Oil.................................................................347 Removal And Installation................................................................348 Parts Identification....................................................................350 Disassembly.............................................................................352 Inspection..............................................................................360 Assembly................................................................................361 HYDROSTATIC MOTOR (SJC).....................................................................371 Replacing the Motor Oil.................................................................371 Removal And Installation................................................................372 Parts Identification....................................................................374 Disassembly and Assembly................................................................376 CHARGE PRESSURE.............................................................................387 Sender Removal And Installation (Non SJC Machines)......................................387 Testing (Non SJC Machines)..............................................................387 Adjusting (Non SJC Machines)............................................................388 Sender Removal And Installation (SJC Machines)..........................................389 Testing (SJC Machines)..................................................................389 Adjusting (SJC Machines)................................................................390 HYDROSTATIC PUMP............................................................................391 Replenishing/High Pressure Relief Valve.................................................391 Removal And Installation................................................................392 Parts Identification (Right Half).......................................................394 Parts Identification (Left Half)........................................................396 Hydraulic Pump Removal And Installation.................................................398 Pump Separation.........................................................................398 Disassembly.............................................................................399 Assembly................................................................................405 HYDROSTATIC PUMP (SJC)......................................................................413 Description.............................................................................413 Hydraulic Controller Removal And Installation...........................................414 Removal And Installation................................................................416 Parts Identification....................................................................418 High Pressure Relief and Bypass Valve...................................................419 Charge Relief Valve.....................................................................420 Disassembly and Assembly................................................................421 Mechanical Neutral Adjustment...........................................................437 Hydraulic Controller Neutral Adjustment.................................................440 DRIVE BELT..................................................................................443 Shield Removal And Installation.........................................................443 Adjusting...............................................................................443 Drive Belt Replacement..................................................................445 Tensioner Pulley Removal And Installation...............................................446 Tensioner Pulley Parts Identification...................................................447 Tensioner Pulley Disassembly............................................................448 Tensioner Pulley Assembly...............................................................449 OIL COOLER..................................................................................451 Removal and Installation................................................................451 DRIVE SYSTEM....................................................................................453 BRAKE.......................................................................................455 Pressure Relief Valve Test..............................................................455 Right Motor Brake Test..................................................................456 Left Motor Brake Test...................................................................457 Block Removal And Installation..........................................................459 Block Disassembly And Assembly..........................................................461 DRIVE COMPONENTS............................................................................463 Track Tension...........................................................................463 Track Tension Adjusting.................................................................463 Track Removal And Installation..........................................................466 Track Idler (Front) Removal And Installation............................................469 Track Idler (Front) Parts Identification................................................471 Track Idler (Front) Disassembly.........................................................472 Track Idler (Front) Assembly............................................................473 Track Idler (Rear) End Play Specifications..............................................476 Track Idler (Rear) Parts Identification.................................................476 Track Idler (Rear) Removal And Installation.............................................476 Track Idler (Rear) Disassembly..........................................................477 Track Idler (Rear) Assembly.............................................................478 Track Roller Assembly End Play Specifications...........................................480 Track Roller Parts Identification.......................................................480 Track Roller Removal And Installation...................................................480 Track Roller Disassembly................................................................481 Track Roller Assembly...................................................................482 Track Housing Removal And Installation..................................................484 Track Damage Identification.............................................................485 MAIN FRAME......................................................................................497 SEAT BAR....................................................................................501 Removal And Installation................................................................501 Assembling Components...................................................................503 Compression Spring Disassembly And Assembly.............................................505 OPERATOR CAB................................................................................507 Gas Cylinder Removal And Installation...................................................507 Gas Cylinder Disassembly................................................................509 Removal And Installation................................................................510 OPERATOR SEAT (SUSPENSION)..................................................................513 Removal And Installation................................................................513 Slide Rail Removal And Installation.....................................................514 Cushion Removal And Installation........................................................514 Back Removal And Installation...........................................................516 Shock Removal And Installation..........................................................516 3-Point Seat Belt Removal And Installation..............................................517 BOB-TACH....................................................................................519 Removal And Installation................................................................519 Bob-Tach Lever And Wedge................................................................520 POWER BOB-TACH..............................................................................523 Removal And Installation................................................................523 Power Bob-Tach Lever And Wedge..........................................................524 LIFT ARMS...................................................................................527 Removal And Installation................................................................527 REAR GRILL..................................................................................531 Removal And Installation................................................................531 REAR DOOR...................................................................................533 Removal And Installation................................................................533 Striker Removal and Installation........................................................534 Striker Disassembly and Assembly........................................................534 Adjusting The Striker...................................................................534 Latch Removal and Installation..........................................................535 FUEL TANK...................................................................................537 Removal And Installation................................................................537 Fuel Level Sender.......................................................................538 Fuel Fill Screen........................................................................538 Fuel Pickup Screen......................................................................539 CONTROL PEDALS..............................................................................541 Removal And Installation................................................................541 Pedal Adjustment........................................................................541 Crossbar Linkage Removal And Installation...............................................542 Lift Foot Pedal Linkage Removal And Installation........................................543 Tilt Foot Pedal Linkage Removal And Installation........................................544 CONTROL PEDALS (ACS)........................................................................545 Foot Sensor Removal And Installation....................................................545 Foot Pedal Removal And Installation.....................................................546 Foot Pedal Linkage Disassembly And Assembly.............................................547 CONTROL PANEL (NON-ADJUSTABLE PINTLES)......................................................549 Removal and Installation................................................................549 Shock Removal And Installation..........................................................552 Shaft Removal And Installation..........................................................552 Shaft Disassembly And Assembly..........................................................552 Linkage Removal And Installation........................................................553 Linkage Adjustment......................................................................556 Linkage Neutral Adjustment..............................................................560 CONTROL PANEL (ADJUSTABLE PINTLES)..........................................................563 Description.............................................................................563 Removal and Installation................................................................564 Shock Removal And Installation..........................................................567 Shaft Removal And Installation..........................................................567 Shaft Disassembly And Assembly..........................................................568 Linkage Removal And Installation........................................................569 Pintle Arm Disassembly and Assembly.....................................................573 Linkage Neutral Adjustment..............................................................575 Linkage Travel Adjustment...............................................................579 CONTROL PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)...........................................583 Removal And Installation................................................................583 CONTROL HANDLE..............................................................................585 Control Lever Removal And Installation..................................................585 Control Lever Boot......................................................................585 CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELCTABLE HAND/FOOT CONTROL..................587 Components Identification...............................................................587 Handle Sensor Removal And Installation..................................................588 Control Handle Removal and Installation.................................................591 Control Handle Disassembly and Assembly.................................................592 Control Lever Removal and Installation..................................................592 Control Lever Boot......................................................................594 CONTROL HANDLE (SELECTABLE JOYSTICK CONTROL) (SJC)..........................................595 Joystick Testing (Right & Left).........................................................595 Joystick Removal (Right & Left).........................................................596 Lever Assembly Removal (Right & Left)...................................................597 ELECTRICAL SYSTEM...............................................................................599 ELECTRICAL SCHEMATIC........................................................................603 ELECTRICAL SYSTEM INFORMATION...............................................................614 Troubleshooting Chart...................................................................616 Description.............................................................................617 Fuse Location...........................................................................618 Relay Switch Location...................................................................618 BATTERY.....................................................................................620 Removal And Installation................................................................620 Servicing...............................................................................621 Using A Booster Battery (Jump Starting).................................................622 ALTERNATOR..................................................................................624 Adjusting The Alternator Belt...........................................................624 Alternator Identification...............................................................624 Charging System Check...................................................................625 Alternator Voltage Test.................................................................626 Low Voltage Test........................................................................627 High Voltage Test.......................................................................627 Removal And Installation................................................................628 Rectifier Continuity (Diode) Test.......................................................629 Alternator Regulator Test...............................................................630 Disassembly.............................................................................630 Stator Continuity Test..................................................................631 Stator Ground Test......................................................................631 Rotor Continuity Test...................................................................631 Rotor Ground Test.......................................................................631 Assembly................................................................................632 STARTER.....................................................................................634 Checking................................................................................634 Removal And Installation................................................................635 Parts Identification....................................................................636 Disassembly and Assembly................................................................637 Inspection And Repair...................................................................640 No Load Test............................................................................642 INSTRUMENT PANEL............................................................................644 Left Panel..............................................................................644 Right Panel (Standard) (With Key Switch)................................................645 Right Panel (Deluxe) (With Keyless Start)...............................................646 Right Panel Setup Display Options (Deluxe)..............................................648 Deluxe Panel Setup......................................................................649 Passwords (Deluxe)......................................................................649 Option And Field Accessory Panels (If Equipped).........................................651 Standard Panel Removal And Installation (Right Side)....................................652 Deluxe Panel Removal And Installation (Right Side)......................................653 Standard & Deluxe Panel Removal And Installation (Left Side)............................654 Front Accessory Panel Removal And Installation..........................................655 LIGHTS......................................................................................656 Front Removal And Installation..........................................................656 Rear Removal And Installation...........................................................657 BOBCAT CONTROLLER...........................................................................658 Identification Chart....................................................................658 Removal And Installation................................................................660 CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC)..............................................662 Removal and Installation................................................................662 Identification Chart....................................................................665 DIAGNOSTICS SERVICE CODES...................................................................668 Display.................................................................................668 Number Codes List.......................................................................669 BICS SYSTEM.................................................................................676 Inspecting The BICS Controller (Engine STOPPED - Key ON)................................676 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....676 Inspecting The Seat Bar Sensor (Engine RUNNING).........................................676 Inspecting The Traction Lock (Engine RUNNING)...........................................676 Inspecting The Lift Arm Bypass Control..................................................677 Additional Inspection For Loaders With Advanced Control System (ACS)....................677 Troubleshooting Chart...................................................................678 Troubleshooting Guide...................................................................679 SEAT BAR SENSOR.............................................................................680 Troubleshooting Chart...................................................................680 Test....................................................................................681 Removal And Installation................................................................682 BICS Circuit Test.......................................................................683 TRACTION LOCK...............................................................................686 Troubleshooting Chart...................................................................686 Description Of The Control System.......................................................687 Inspecting The Control System...........................................................687 ADVANCED CONTROL SYSTEM (ACS)...............................................................688 Components Identification...............................................................688 Troubleshooting Guide...................................................................690 Controller, Connector And Wire Identification...........................................691 ACS Controller Removal And Installation.................................................692 Handle Sensor Connector.................................................................693 Switch Handle Removal...................................................................694 Switch Handle Installation..............................................................696 Actuators Disassembly and Assembly......................................................699 Handle Lock Solenoid Removal And Installation...........................................700 Handle Lock Solenoid Disassembly And Assembly...........................................701 Handle Lock Solenoid Connector..........................................................702 Calibration Procedure...................................................................703 Foot Sensor Disassembly And Assembly....................................................705 Foot Sensor Connector...................................................................705 Foot Lock Solenoid Removal And Installation.............................................706 Foot Lock Solenoid Connector............................................................707 ELECTRICAL/HYDRAULIC CONTROLS REFERENCE.....................................................708 Controls Identification Chart...........................................................708 ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (SELECTABLE JOYSTICK CONTROL) (SJC).................710 Controls Identification Chart...........................................................710 FLYWHEEL RPM SENSOR.........................................................................714 Adjustment..............................................................................714 SERVICE PC (LAPTOP COMPUTER)................................................................716 Connecting The Service PC To Remote Start Tool..........................................716 CALIBRATION.................................................................................718 Description.............................................................................718 Actuator Testing........................................................................718 Lift and Tilt Calibration Procedure (SJC)...............................................721 Hydrostatic Pump Calibration (SJC)......................................................722 Calibration Procedure (ACS).............................................................728 SPEED SENSOR (SELECTABLE JOYSTICK CONTROL) (SJC)............................................730 Description.............................................................................730 Testing.................................................................................730 Removal and Installation................................................................732 ENGINE SERVICE..................................................................................736 TROUBLESHOOTING.............................................................................738 Chart...................................................................................738 ENGINE SPEED CONTROL........................................................................740 Removal And Installation................................................................740 Disassembly.............................................................................741 ENGINE SPEED CONTROL (SELECTABLE JOYSTICK CONTROL) (SJC)....................................742 Removal and Installation................................................................742 Disassembly and Assembly................................................................744 MUFFLER.....................................................................................746 Removal And Installation................................................................746 AIR CLEANER.................................................................................748 Removal And Installation................................................................748 RADIATOR....................................................................................750 Removal And Installation................................................................750 COOLING FAN.................................................................................754 Drive Tension Pulley Removal And Installation...........................................754 Gearbox/Blower Housing Removal And Installation.........................................755 Blower Housing Grill Removal And Installation...........................................757 Blower Disassembly And Assembly.........................................................757 Gearbox Parts Identification............................................................759 Gearbox Disassembly.....................................................................760 Gearbox Assembly........................................................................765 Gearbox Checking Backlash...............................................................770 ENGINE COMPONENTS AND TESTING...............................................................774 Compression Checking....................................................................774 Glow Plugs Checking.....................................................................775 Glow Plugs Removal And Installation.....................................................775 Fuel Shut-Off Solenoid, Checking........................................................776 Fuel Shut-Off Solenoid Removal And Installation.........................................777 Fuel Injection Pump Removal And Installation............................................778 Timing The Injection Pump...............................................................781 Fuel Injector Removal And Installation..................................................783 Checking Nozzle Injection Pressure......................................................784 Nozzle Spraying Condition...............................................................785 Valve Seat Tightness....................................................................785 Valve Clearance Adjustment..............................................................786 Valve Timing, Checking..................................................................787 ENGINE......................................................................................788 Removal And Installation................................................................788 Engine Mount Replacement................................................................796 FLYWHEEL AND HOUSING........................................................................798 Flywheel Removal And Installation.......................................................798 Ring Gear Removal And Installation......................................................798 Housing Removal And Installation........................................................799 RECONDITIONING THE ENGINE...................................................................802 Cylinder Head Removal And Installation..................................................802 Cylinder Head Disassembly And Assembly..................................................805 Cylinder Head Servicing.................................................................806 Cylinder Head Top Clearance.............................................................806 Valve Guide Checking....................................................................807 Reconditioning The Valve And Valve Seat.................................................809 Valve Spring............................................................................810 Rocker Arm And Shaft Checking...........................................................811 Timing Gearcase Cover Removal And Installation..........................................811 Idler Gear And Camshaft Removal And Installation........................................814 Camshaft Servicing......................................................................815 Idler Gear And Shaft Servicing..........................................................816 Timing Gears Checking Backlash..........................................................817 Fuel Camshaft Removal And Installation..................................................817 Fuel Camshaft Governor..................................................................818 Crankshaft Gear Removal And Installation................................................818 Oil Pump Removal And Installation.......................................................819 Oil Pump Service........................................................................819 Checking Engine Oil Pressure............................................................820 Valve Tappets...........................................................................821 Piston And Connecting Rod Removal And Installation......................................821 Piston And Connecting Rod Servicing.....................................................823 Connecting Rod Alignment................................................................826 Crankshaft And Bearings Removal And Installation........................................826 Crankshaft And Bearings, Servicing......................................................828 Cylinder Bore, Checking.................................................................832 Water Pump Removal And Installation.....................................................833 Water Pump Disassembly And Assembly.....................................................833 TURBOCHARGER................................................................................834 Checking................................................................................834 Description.............................................................................834 Removal And Installation................................................................835 HEATING, VENTILATION, AIR CONDITIONING..........................................................838 AIR CONDITIONING SYSTEM FLOW................................................................841 Principals..............................................................................841 Chart...................................................................................842 COMPONENTS..................................................................................844 Identification..........................................................................844 SAFETY......................................................................................848 Safety Equipment........................................................................848 REGULAR MAINTENANCE.........................................................................850 Filter Elements Removal And Installation................................................850 Compressor Drive Belt Inspection........................................................851 Cleaning The Condenser..................................................................852 BASIC TROUBLESHOOTING.......................................................................854 Poor A/C Performance....................................................................854 Cleaning The A/C Evaporator Coil & Heater Coil..........................................854 Compressor Drive Belt Inspection........................................................855 Checking The Electrical System..........................................................856 Engine Coolant Bypassing The Heater Valve...............................................863 Heater Valve Not Opening Or Closing.....................................................864 GENERAL AIR CONDITIONING SERVICE GUIDELINES.................................................866 Compressor Oil..........................................................................866 Compressor Oil Check....................................................................867 Component Replacement And Refrigeration Leaks...........................................868 SYSTEM TROUBLESHOOTING CHART................................................................870 Gauge Pressure Related Troubleshooting..................................................871 TEMPERATURE/PRESSURE........................................................................874 Chart...................................................................................874 AIR CONDITIONING SERVICE....................................................................876 Chart...................................................................................876 SYSTEM CHARGING AND RECLAMATION.............................................................878 Reclamation Procedure...................................................................878 Charging Procedure With A Manifold Gauge Set............................................881 Charging Procedure......................................................................882 COMPRESSOR..................................................................................884 Removal And Installation................................................................884 Compressor Clutch Disassembly...........................................................885 CONDENSER...................................................................................890 Removal And Installation................................................................890 RECEIVER/DRIER..............................................................................892 Removal And Installation................................................................892 PRESSURE RELIEF VALVE.......................................................................894 Removal And Installation................................................................894 PRESSURE SWITCH.............................................................................896 Removal And Installation................................................................896 EVAPORATOR/HEATER UNIT......................................................................898 Removal And Installation................................................................898 Disassembly And Assembly................................................................900 THERMOSTAT..................................................................................902 Removal And Installation................................................................902 EXPANSION VALVE.............................................................................904 Removal And Installation................................................................904 EVAPORATOR..................................................................................906 Removal And Installation................................................................906 HEATER COIL.................................................................................908 Removal And Installation With A/C.......................................................908 Removal And Installation Without A/C....................................................909 HEATER/AC FAN...............................................................................912 Removal And Installation................................................................912 Disassembly And Assembly................................................................913 Wire Connector Removal and Installation.................................................915 HEATER VALVE................................................................................918 Removal And Installation................................................................918 Disassembly And Assembly................................................................918 SPECIFICATIONS..................................................................................920 LOADER SPECIFICATIONS.......................................................................922 Loader Dimensions.......................................................................922 Performance.............................................................................923 Controls................................................................................923 Engine..................................................................................923 Hydraulic System........................................................................924 Electrical..............................................................................924 Drive System............................................................................925 Capacities..............................................................................925 Tracks..................................................................................925 Ground Pressure.........................................................................925 ENGINE SPECIFICATIONS - KUBOTA V2003-M-DI-T.................................................926 Fuel Injection Nozzles..................................................................926 Fuel Injection Pump.....................................................................926 Cylinder Head...........................................................................926 Valves..................................................................................926 Valve Springs...........................................................................927 Valve Timing............................................................................927 Rocker Arms.............................................................................927 Camshaft................................................................................927 Tappet..................................................................................927 Cylinder Liner..........................................................................928 Piston Rings............................................................................928 Pistons.................................................................................928 Connecting Rod..........................................................................928 Oil Pump................................................................................928 Crankshaft..............................................................................929 Timing Gear.............................................................................929 Thermostat..............................................................................929 ENGINE SPECIFICATIONS - KUBOTA V2403-M-DI-T.................................................930 Fuel Injection Nozzles..................................................................930 Fuel Injection Pump.....................................................................930 Cylinder Head...........................................................................930 Valves..................................................................................930 Valve Springs...........................................................................931 Valve Timing............................................................................931 Rocker Arms.............................................................................931 Camshaft................................................................................931 Tappet..................................................................................931 Cylinder Liner..........................................................................932 Piston Rings............................................................................932 Pistons.................................................................................932 Connecting Rod..........................................................................932 Oil Pump................................................................................932 Crankshaft..............................................................................933 Timing Gear.............................................................................933 Thermostat..............................................................................933 TORQUE SPECIFICATIONS FOR BOLTS.............................................................934 Torque For General SAE Bolts............................................................934 Torque For General Metric Bolts.........................................................935 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................936 O-ring Face Seal Connection.............................................................936 Straight Thread O-ring Fitting..........................................................937 Tubelines And Hoses.....................................................................937 Flare Fitting...........................................................................937 O-ring Flare Fitting....................................................................938 Port Seal Fitting.......................................................................940 HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS..................................................942 Specifications..........................................................................942 CONVERSIONS.................................................................................944 Decimal And Millimeter Equivalents......................................................944 U.S. To Metric Conversion...............................................................944 SERVICE MANUAL REVISION.........................................................................946 Revision No: T190 - 1.......................................................................946 Revision No: T190 - 2.......................................................................948 Revision No: T190 - 3.......................................................................950 Revision No: T190 - 4.......................................................................952 Revision No: T190 - 5.......................................................................954 Revision No: T190 - 6.......................................................................956 Revision No: T190 - 7.......................................................................958 Revision No: T190 - 8.......................................................................960 Revision No: T190 - 9.......................................................................962
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V
