Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Bobcat T200 Turbo T200 Turbo High Flow Loader Service Manual 6901397 (10-12) – PDF DOWNLOAD
$33.95
Bobcat T200 Turbo T200 Turbo High Flow Loader Service Manual 6901397 (10-12) – PDF DOWNLOAD
S/N 518915001 & Above
S/N 516815001 & Above
S/N 517515001 & Above
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Bobcat T200 Turbo T200 Turbo High Flow Loader Service Manual 6901397 (10-12) – PDF DOWNLOAD
FILE DETAILS:
Bobcat T200 Turbo T200 Turbo High Flow Loader Service Manual 6901397 (10-12) – PDF DOWNLOAD
Language : English
Pages : 870
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat T200 Turbo T200 Turbo High Flow Loader Service Manual 6901397 (10-12) – PDF DOWNLOAD
S/N 518915001 & Above
S/N 516815001 & Above
S/N 517515001 & 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 T200 Turbo T200 Turbo High Flow Loader Service Manual 6901397 (10-12) – 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 AND MAINTENANCE.......................................................................... 19 LIFTING AND BLOCKING THE LOADER............................................................. 21 Procedure............................................................................... 21 LIFT ARM SUPPORT DEVICE..................................................................... 23 Engaging The Lift Arm Support Device.................................................... 23 Disengaging The Lift Arm Support Device................................................. 25 OPERATOR CAB................................................................................ 27 Raising The Operator Cab................................................................ 27 Lowering the Operator Cab............................................................... 28 Emergency Exit.......................................................................... 29 TRANSPORTING THE BOBCAT LOADER.............................................................. 31 Procedure............................................................................... 31 Stopping The Bobcat Loader.............................................................. 31 TOWING THE LOADER........................................................................... 33 Procedure (S/N 517515079, 516815098, 518916041 And Below)............................... 33 Procedure (S/N 517515079, 516815098, 518916041 and Above)............................... 35 REMOTE START................................................................................ 37 Procedure For Loader Without Attachments Control Harness................................ 37 Procedure For Loader With Attachments Control Harness................................... 38 Procedure............................................................................... 40 SERVICE SCHEDULE............................................................................ 41 Chart................................................................................... 41 AIR CLEANER SERVICE......................................................................... 43 Replacing Filter Element................................................................ 43 ENGINE COOLING SYSTEM....................................................................... 45 Cleaning The Cooling System............................................................. 45 FUEL SYSTEM................................................................................. 47 Fuel Specifications..................................................................... 47 Filling the Fuel Tank................................................................... 47 Fuel Filter............................................................................. 48 Fuel Lift Pump Strainer................................................................. 49 Removing Air From The Fuel System....................................................... 49 ENGINE LUBRICATION SYSTEM................................................................... 51 Checking Engine Oil..................................................................... 51 Replacing Oil And Filter................................................................ 52 HYDRAULIC / HYDROSTATIC SYSTEM.............................................................. 53 Checking And Adding Fluid............................................................... 53 Hydraulic / Hydrostatic Filter Replacement.............................................. 53 Replacing Hydraulic Fluid (518911353 & Below)........................................... 54 Replacing Hydraulic Fluid (518911354 & Above)........................................... 56 FAN GEARBOX................................................................................. 57 Checking And Adding Oil................................................................. 57 BOB-TACH.................................................................................... 59 Inspection And Maintenance.............................................................. 59 POWER BOB-TACH (OPTION)..................................................................... 61 Inspection And Maintenance.............................................................. 61 LUBRICATING THE LOADER...................................................................... 63 Procedure............................................................................... 63 HYDRAULIC SYSTEM................................................................................ 65 HYDRAULIC / HYDROSTATIC SCHEMATICS.......................................................... 71 HYDRAULIC SYSTEM INFORMATION................................................................ 87 Glossary Of Hydraulic / Hydrostatic Symbols For Loaders................................. 87 Troubleshooting......................................................................... 91 Tighten Procedures...................................................................... 92 CYLINDER (LIFT)............................................................................. 93 Checking................................................................................ 93 Removal And Installation................................................................ 93 Parts Identification.................................................................... 95 Disassembly............................................................................. 96 Assembly................................................................................ 97 CYLINDER (TILT).............................................................................101 Checking................................................................................101 Removal And Installation................................................................101 Rod End Seal............................................................................102 Parts Identification....................................................................104 Disassembly.............................................................................105 Assembly................................................................................107 CYLINDER (POWER BOB-TACH)...................................................................111 Checking................................................................................111 Removal And Installation................................................................112 Parts Identification....................................................................113 Disassembly.............................................................................114 Assembly................................................................................115 MAIN RELIEF VALVE...........................................................................119 Checking The Main Relief Valve At Front Auxiliary Hydraulics............................119 Removal And Installation................................................................120 Adjustment..............................................................................121 HYDRAULIC CONTROL VALVE (FOOT CONTROL)......................................................123 Removal And Installation (S/N 518915181 & Below)........................................123 Removal And Installation (S/N 518915182 & Above)........................................130 BICS™ Valve, Removal And Installation...................................................135 BICS™ Valve, Lift Arm Bypass Orifice Disassembly And Assembly...........................136 BICS™ Valve, Check Valve Disassembly And Assembly (S/N 518916163 & Below)...............137 BICS™ Valve, Check Valve Disassembly And Assembly (S/N 518916164 & Above)...............138 BICS™ Valve, Lock Valve Disassembly And Assembly........................................139 BICS™ Valve, Solenoid Disassembly And Assembly..........................................140 BICS™ Valve, Solenoid Testing...........................................................141 Identification Chart....................................................................142 Load Check Valve........................................................................143 Main Relief Valve.......................................................................144 Port Relief Valve, Tilt Spool (Linkage End).............................................144 Port Relief Valve, Lift Spool (Bonnet End)..............................................145 Anti-Cavitation Valve / Port Relief Valve, Tilt Spool (Bonnet End)......................145 Anti-Cavitation Valve, Lift Spool (Linkage End).........................................146 Rubber Boot.............................................................................146 Lift And Tilt Lock Block................................................................147 Lift Spool and Detent...................................................................148 Tilt Spool Removal And Installation.....................................................156 Auxiliary Spool Removal And Installation (Bonnet End)...................................158 Auxiliary Spool Removal And Installation (Linkage End)..................................159 Auxiliary Plug Removal And Installation.................................................160 Auxiliary Electric Solenoid Disassembly.................................................161 Port Relief-Auxiliary Section Disassembly...............................................162 Cleaning And Inspection.................................................................162 HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS).....................................163 Actuator Removal And Installation (In Loader) (S/N 518915181 & Below)...................163 Removal And Installation (S/N 518915181 & Below)........................................165 Actuator Removal And Installation (In Loader) (S/N 518915182 & Above)...................171 Actuator Removal And Installation (Out Of Loader).......................................173 Removal And Installation (S/N 518915182 & Above)........................................174 BICS™ Valve, Removal And Installation...................................................179 BICS™ Valve, Lift Arm Bypass Orifice Disassembly And Assembly...........................181 BICS™ Valve, Check Valve Disassembly And Assembly.......................................182 BICS™ Valve, Lock Valve Disassembly And Assembly........................................183 BICS™ Valve, Solenoid Disassembly And Assembly..........................................184 BICS™ Valve, Solenoid Testing...........................................................185 Identification Chart....................................................................186 Identification Chart....................................................................187 Lift Base End Restrictor................................................................188 Load Check Valve........................................................................188 Main Relief Valve.......................................................................189 Port Relief Valve.......................................................................190 Anti-Cavitation Valve / Port Relief Valve...............................................191 Anti-Cavitation Valve...................................................................192 Lift Spool Removal......................................................................193 Lift Spool Removal And Installation.....................................................194 Lift and Tilt Spool Disassembly And Assembly............................................195 Auxiliary Spool Removal And Installation................................................196 Auxiliary Electric Solenoid Disassembly.................................................197 Port-Auxiliary Section Disassembly......................................................198 Cleaning And Inspection.................................................................198 LIFT ARM BYPASS CONTROL VALVE...............................................................199 Inspecting..............................................................................199 Additional Inspection For Loaders With Hand Controls....................................199 Removal And Installation................................................................199 Disassembly And Assembly................................................................201 HYDRAULIC PUMP (ALUMINUM)...................................................................203 Checking The Output Of The Pump (518916260 & Below).....................................203 Removal And Installation (518916260 & Below)............................................204 Parts Identification (518916260 & Below)................................................206 Disassembly (518916260 & Below).........................................................207 Inspection (518916260 & Below)..........................................................209 Assembly (518916260 & Below)............................................................210 HYDRAULIC PUMP (ALUMINUM HI-FLOW)...........................................................213 Checking The Output Of The High Flow Pump (518916427 & Below)...........................213 HYDRAULIC PUMP (ALUMINUM HI-FLOW)...........................................................214 Checking The Output Of The High Flow Pump (518916427 & Below)...........................214 Removal And Installation (518916427 & Below)............................................215 Parts Identification (518916427 & Below)................................................217 Disassembly (518916427 & Below).........................................................218 Inspection (518916427 & Below)..........................................................222 Assembly (518916427 & Below)............................................................224 HYDRAULIC PUMP (CAST IRON)..................................................................227 Check Output of the Cast Iron Hydraulic Pump (518916261 & Above)........................227 Removal And Installation (518916261 & Above)............................................229 HYDRAULIC PUMP (CAST IRON)..................................................................231 Disassembly And Assembly (518916261 & Above)............................................231 HYDRAULIC PUMP (CAST IRON HI-FLOW)..........................................................237 Hydraulic Pump Test (518916428 & Above).................................................237 Inline Hydraulic Pump Test (518916428 & Above) (Standard)...............................238 Inline Hydraulic Pump Test (518916428 & Above) (HI- FLOW)...............................240 High Flow Relief Adjustment Procedure (518916428 & Above)...............................242 High Flow Relief Valve Removal and Installation (518916428 & Above).....................244 Removal And Installation (518916428 & Above)............................................246 Identification (518916428 & Above)......................................................248 Disassembly And Assembly (518916428 & Above)............................................249 HYDRAULIC / HYDROSTATIC FILTER..............................................................259 Housing Removal And Installation (S/N 518913532 & Below)................................259 Mount Removal And Installation..........................................................260 Housing Removal And Installation (S/N 518913533 & Above)................................261 HYDRAULIC FLUID RESERVOIR...................................................................263 Draining The Hydraulic Fluid Reservoir..................................................263 Removal And Installation................................................................263 Hydraulic Fluid Screen..................................................................265 BUCKET POSITION VALVE.......................................................................267 Solenoid Removal And Installation.......................................................267 Solenoid Testing........................................................................267 Removal And Installation................................................................268 Disassembly And Assembly................................................................269 SELECT VALVE................................................................................271 Checking The High Flow Pump Relief Valve (518916427 & Below)............................271 Removal And Installation (518916427 & Below)............................................273 Disassembly And Assembly (518916427 & Below)............................................275 Solenoid Testing (518916427 & Below)....................................................280 REAR AUXILIARY DIVERTER VALVE...............................................................281 Disassembly.............................................................................281 Inspection..............................................................................281 Solenoid Testing........................................................................282 Assembly................................................................................282 POWER BOB-TACH BLOCK........................................................................283 Removal And Installation................................................................283 Disassembly And Assembly................................................................285 AUXILIARY PRESSURE RELEASE (ACCUMULATOR)....................................................291 Removal and Installation (518916010 & Below)............................................291 Disassembly And Assembly (518916010 & Below)............................................292 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.....................................................293 Removal And Installation (518916011 & Above)............................................293 Disassembly And Assembly (518916011 & Above)............................................293 HYDROSTATIC SYSTEM..............................................................................295 HYDROSTATIC SYSTEM INFORMATION..............................................................297 Troubleshooting Chart...................................................................297 Replenishing Valve Function.............................................................298 HYDROSTATIC MOTOR...........................................................................299 Removal And Installation................................................................299 Parts Identification....................................................................301 Disassembly.............................................................................303 Inspection..............................................................................311 Assembly................................................................................312 Filling.................................................................................320 CHARGE PRESSURE SENDER......................................................................323 Removal and Installation................................................................323 Checking Charge Pressure................................................................324 HYDROSTATIC PUMP............................................................................325 Removal And Installation................................................................325 Replenishing / High Pressure Relief Valve(s)............................................327 Parts Identification (Right Half).......................................................328 Parts Identification (Left Half)........................................................330 Hydraulic Pump Removal And Installation.................................................332 Disassembly.............................................................................333 Assembly................................................................................341 DRIVE BELT..................................................................................349 Shield Removal And Installation.........................................................349 Adjustment..............................................................................350 Replacement.............................................................................350 Tensioner Pulley Removal And Installation...............................................351 Tensioner Pulley Disassembly And Assembly...............................................352 Tensioner Pulley Tension Spring.........................................................353 OIL COOLER..................................................................................355 Removal and Installation................................................................355 Removal And Installation With STC (Seal Tight Connector)................................356 DRIVE SYSTEM....................................................................................357 BRAKE (S/N 518916041 AND BELOW).............................................................359 Switch Operated Parking Brake...........................................................359 Block Removal And Installation..........................................................359 Block Disassembly And Assembly..........................................................362 Traction Lock Bypass Knob...............................................................362 BRAKE (S/N 518916042 AND ABOVE).............................................................363 Switch Operated Parking Brake...........................................................363 Block Removal And Installation..........................................................363 Block Disassembly And Assembly..........................................................365 DRIVE COMPONENTS............................................................................367 Track Checking..........................................................................367 Track Adjustment........................................................................368 Track Removal And Installation..........................................................369 Track Idler (Front) End Play Specifications.............................................372 Track Idler (Front) Removal And Installation............................................372 Track Idler (Front) Parts Identification (S/N 518916540 & Below)........................375 Track Idler (Front) Disassembly (S/N 518916540 & Below).................................376 Track Idler (Front) Assembly (S/N 518916540 & Below)....................................377 Track Idler (Rear) End Play Specifications (S/N 518916540 & Below)......................380 Track Idler (Rear) Removal And Installation (S/N 518916540 & Below).....................380 Track Idler (Rear) Parts Identification.................................................380 Track Idler (Rear) Disassembly (S/N 518916540 & Below)..................................381 Track Idler (Rear) Assembly (S/N 518916540 & Below).....................................382 Track Roller Assembly End Play Specifications (S/N 518916540 & Below)...................384 Track Roller Parts Identification.......................................................384 Track Roller Removal And Installation (S/N 518916540 & Below)...........................384 Track Roller Disassembly (S/N 518916540 & Below)........................................385 Track Roller Assembly...................................................................386 Track Idler (Front) Parts Identification (S/N 518916541 & Above)........................388 Track Idler (Front) Disassembly (S/N 518916541 & Above).................................389 Track Idler (Front) Assembly............................................................390 Track Idler (Rear) End Play Specifications (S/N 518916541 & Above)......................393 Track Idler (Rear) Parts Identification.................................................393 Track Idler (Rear) Removal And Installation.............................................393 Track Idler (Rear) Disassembly (S/N 518916541 & Above)..................................394 Track Roller Assembly End Play Specifications (S/N 518916541 & Above)...................397 Track Roller Parts Identification.......................................................397 Track Roller Removal And Installation...................................................397 Track Roller Disassembly (S/N 518916541 & Above)........................................398 Track Housing Removal And Installation..................................................401 Track Damage Identification.............................................................402 MAINFRAME.......................................................................................413 SEAT BAR....................................................................................415 Removal And Installation................................................................415 Assembling Components...................................................................416 Compression Spring Disassembly And Assembly.............................................418 OPERATOR CAB................................................................................419 Gas Cylinder Removal And Installation...................................................419 Gas Cylinder Disassembly And Assembly...................................................420 Removal And Installation................................................................421 OPERATOR SEAT...............................................................................423 Removal And Installation................................................................423 Seat Belt Removal And Installation......................................................423 OPERATOR SEAT (SUSPENSION)..................................................................425 Removal And Installation................................................................425 Slide Rail Removal And Installation.....................................................426 Cushion Removal And Installation........................................................426 Back Removal And Installation...........................................................427 Shock Removal And Installation..........................................................428 BOB-TACH....................................................................................429 Inspection And Maintenance..............................................................429 Bob-Tach Lever And Wedge................................................................430 Removal And Installation................................................................432 Pivot Pin Bushing And Seal Replacement..................................................434 POWER BOB-TACH..............................................................................435 Inspection And Maintenance..............................................................435 Power Bob-Tach Lever And Wedge..........................................................436 Removal And Installation................................................................437 Pivot Pin Bushing And Seal Replacement..................................................439 LIFT ARMS...................................................................................441 Removal And Installation................................................................441 REAR GRILL..................................................................................445 Removal And Installation................................................................445 REAR DOOR...................................................................................447 Removal And Installation................................................................447 Adjusting The Rear Door Latch (S/N 516815093, 517515070, 518915871 & Below.)............448 Striker Removal And Installation (S/N 516815094, 517515071, 518915872 & Above.).........448 Adjusting The Striker (S/N 516815094, 517515071, 518915872 & Above.)....................449 Latch Removal And Installation (S/N 516815094, 517515071, 518915872 & Above.)...........449 FUEL TANK...................................................................................451 Removal And Installation................................................................451 Fuel Level Sender.......................................................................454 Fuel Pick-up Screen / Check Valve.......................................................454 CONTROL PEDALS..............................................................................455 Control Pedal Removal And Installation..................................................455 Control Pedal Adjustment................................................................455 Crossbar Linkage Removal And Installation...............................................455 Crossbar Linkage Inspection.............................................................456 CONTROL PANEL...............................................................................457 Removal and Installation................................................................457 CONTROL PEDALS (ACS)........................................................................459 Foot Sensor Removal And Installation....................................................459 Foot Pedal Removal And Installation.....................................................460 Foot Pedal Linkage Disassembly And Assembly.............................................460 CONTROL HANDLE..............................................................................461 Shock Removal And Installation..........................................................461 Shaft Removal And Installation..........................................................461 Shaft Disassembly And Assembly..........................................................462 Lever Removal And Installation..........................................................462 Rubber Boot Replacement.................................................................463 Linkage Removal And Installation........................................................464 Linkage Adjustment......................................................................467 Linkage Neutral Adjustment..............................................................469 CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) advanced hand control........................473 Components Identification...............................................................473 Handle Sensor Removal And Installation..................................................473 Control Handle Removal and Installation.................................................477 Control Handle Disassembly and Assembly.................................................478 Control Lever Removal and Installation..................................................478 Control Lever Boot......................................................................479 CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND / FOOT CONTROL...............481 Components Identification...............................................................481 Handle Sensor Removal And Installation..................................................481 Control Handle Removal and Installation.................................................485 Control Handle Disassembly and Assembly.................................................486 Control Lever Removal and Installation..................................................486 Control Lever Removal and Installation (Cont’d).........................................487 Control Lever Boot......................................................................487 ELECTRICAL SYSTEM & ANALYSIS....................................................................489 ELECTRICAL SCHEMATICS.......................................................................493 ELECTRICAL SYSTEM INFORMATION...............................................................499 Troubleshooting Chart...................................................................501 Description.............................................................................502 Fuse Location...........................................................................504 Relay Switch Location...................................................................504 Solenoid Test...........................................................................505 BATTERY.....................................................................................507 Removal And Installation................................................................507 Servicing The Battery...................................................................508 Using A Booster Battery.................................................................509 ALTERNATOR (90 AMP).........................................................................511 Adjusting The Alternator Belt...........................................................511 Alternator Identification...............................................................511 Charging System Check...................................................................512 Alternator Voltage Test.................................................................513 Low Voltage Test........................................................................513 High Voltage Test.......................................................................514 Removal And Installation................................................................515 Rectifier Continuity (Diode) Test.......................................................516 Alternator Regulator Test...............................................................517 Disassembly.............................................................................517 Stator Continuity Test..................................................................518 Stator Ground Test......................................................................518 Rotor Continuity Test...................................................................518 Rotor Ground Test.......................................................................518 Assembly................................................................................519 STARTER (NIPPONDENSO).......................................................................521 Removal And Installation................................................................521 Parts Identification....................................................................522 Disassembly And Assembly................................................................523 External Pinion.........................................................................526 Inspection And Repair...................................................................527 No Load Test............................................................................531 STARTER (VALEO).............................................................................533 Checking................................................................................533 Removal And Installation................................................................534 Parts Identification....................................................................535 Disassembly and Assembly................................................................536 Inspection And Repair...................................................................539 No Load Test............................................................................541 INSTRUMENT PANEL............................................................................543 Left Panel (Standard)...................................................................543 Right Panel-Standard Instrument Panel (With Key Switch).................................544 Right Panel (Deluxe) (With Keyless Start)...............................................545 Right Panel Setup Display Options (Deluxe)..............................................547 Passwords...............................................................................548 Option And Field Accessory Panels.......................................................550 Standard Panel Removal And Installation (Right Side)....................................551 Deluxe Panel Removal And Installation (Right Side)......................................552 Standard And Deluxe Panel Removal And Installation (Left Side)..........................553 Front Accessory Panel Removal And Installation..........................................554 LIGHTS......................................................................................557 Front Removal And Installation..........................................................557 Rear Removal And Installation...........................................................558 BOBCAT CONTROLLER...........................................................................559 Identification Chart (S/N 518916788 & Below)............................................559 BOBCAT CONTROLLER (CONT’D)..................................................................560 Identification Chart (S/N 518916789 & Above)............................................560 Removal And Installation................................................................562 DIAGNOSTICS SERVICE CODES...................................................................565 Display.................................................................................565 BICS™ SYSTEM................................................................................567 Inspecting The BICS™ Controller (Engine STOPPED - Key ON)...............................567 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....567 Inspecting The Seat Bar Sensor (Engine RUNNING).........................................567 Inspecting The Traction Lock (Engine RUNNING)...........................................567 Inspecting The Lift Arm Bypass Control..................................................567 Additional Inspection For Loaders With Advanced Hand Controls...........................568 Troubleshooting Chart...................................................................569 Troubleshooting Guide...................................................................570 SEAT BAR SENSOR.............................................................................571 Troubleshooting Chart...................................................................571 Test....................................................................................572 Removal And Installation................................................................573 BICS™ Circuit Test......................................................................574 TRACTION LOCK...............................................................................575 Troubleshooting Chart...................................................................575 Description Of The Control System.......................................................576 Inspecting The Control System...........................................................576 Parking Brake Solenoid Removal And Installation (S/N 518916040 & Below).................577 Parking Brake Solenoid Removal And Installation (S/N 518916041 & Above).................578 Traction Lock Bypass Knob...............................................................579 ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND CONTROL.........................................581 Components Identification...............................................................581 Troubleshooting Guide...................................................................582 Controller, Connector And Wire Identification...........................................583 ACS Controller Removal And Installation.................................................584 Handle Sensor Connector.................................................................585 Switch Handle Removal...................................................................586 Switch Handle Installation..............................................................588 Actuators Disassembly and Assembly......................................................591 ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND / FOOT CONTROL................................593 Components Identification...............................................................593 Troubleshooting Guide...................................................................595 Controller, Connector And Wire Identification...........................................596 ACS Controller Removal And Installation.................................................597 Handle Sensor Connector.................................................................598 Switch Handle Removal...................................................................599 Switch Handle Installation..............................................................601 Actuators Disassembly and Assembly......................................................604 Handle Lock Solenoid Removal And Installation...........................................605 Handle Lock Solenoid Disassembly And Assembly...........................................605 Handle Lock Solenoid Connector..........................................................606 Calibration Of The ACS System...........................................................607 Switchable Hand / Foot Controls Calibration Procedure...................................607 Hand Controls Only Calibration Procedure................................................608 Foot Sensor Disassembly And Assembly....................................................610 Foot Sensor Connector...................................................................610 Foot Lock Solenoid Removal And Installation.............................................611 Foot Lock Solenoid Connector............................................................611 ELECTRICAL / HYDRAULIC CONTROLS REFERENCE...................................................613 Controls Identification Chart...........................................................613 ENGINE SERVICE..................................................................................615 TROUBLESHOOTING.............................................................................617 Chart...................................................................................617 ENGINE SPEED CONTROL........................................................................619 Removal And Installation................................................................619 Speed Control Cable.....................................................................620 Speed Control Linkage...................................................................621 MUFFLER.....................................................................................623 Removal And Installation................................................................623 AIR CLEANER.................................................................................625 Housing Removal And Installation........................................................625 RADIATOR....................................................................................627 Oil Cooler Removal And Installation.....................................................627 COOLING FAN.................................................................................629 Drive Tension Pulley Removal And Installation...........................................629 Gearbox / Blower Housing Removal And Installation.......................................630 Blower Removal And Installation.........................................................633 Gearbox Parts Identification............................................................634 Gearbox Disassembly.....................................................................635 Gearbox Assembly........................................................................640 Gearbox, Checking Backlash..............................................................645 ENGINE COMPONENTS AND TESTS.................................................................649 Engine Compression, Checking............................................................649 Glow Plug, Checking.....................................................................650 Fuel Shut-Off Solenoid, Checking........................................................651 Fuel Shut-Off Solenoid Removal and Installation.........................................652 Fuel Injection Pump Removal.............................................................652 Fuel Injection Pump Timing..............................................................654 Fuel Injection Pump Installation........................................................655 Fuel Injector Removal and Installation..................................................657 Fuel Injector, Checking.................................................................658 Fuel Injector Disassembly...............................................................659 Fuel Injector Assembly..................................................................660 Timing Belt Inspection..................................................................662 Timing Belt Removal.....................................................................662 Timing Belt Installation................................................................663 Timing Belt, Replacement In the Loader..................................................667 Valve Clearance Adjustment..............................................................672 Valve Timing, Checking..................................................................673 Thermostat, Oil Pressure Control Valves And Heater Connections..........................675 ENGINE AND ENGINE MOUNTS....................................................................679 Removal And Installation................................................................679 Engine Mount Replacement................................................................685 FLYWHEEL AND HOUSING........................................................................687 Flywheel Removal And Installation.......................................................687 Ring Gear Removal And Installation......................................................687 Flywheel Housing Removal And Installation...............................................687 RPM SENSOR..................................................................................689 Adjustment..............................................................................689 RECONDITIONING THE ENGINE...................................................................691 Deutz Engine Tools Identification Chart.................................................691 Disassembly.............................................................................692 Assembly................................................................................696 Cylinder, Checking......................................................................712 Camshaft Bearing, Checking..............................................................713 Camshaft Bearing, Removal And Installation..............................................713 Control Rod Guide Bushing Removal.......................................................714 Control Rod Guide Bushing Installation..................................................716 Rear Cover Seal Removal And Installation................................................720 Crankshaft, Checking....................................................................721 Connecting Rod, Checking................................................................723 Piston, Checking........................................................................725 Piston Pin, Checking....................................................................726 Piston Rings Installation...............................................................726 Piston Installation On the Connecting Rod...............................................727 Cylinder Head Disassembly...............................................................729 Valves, Checking........................................................................729 Valve Seats, Checking...................................................................730 Valve Spring, Checking..................................................................731 Cylinder Head Assembly..................................................................731 Rocker Arm and Bracket, Checking........................................................732 Front Cover Disassembly.................................................................733 Front Cover Assembly....................................................................738 Turbo Charger Removal and Installation..................................................747 Crankshaft Gear Mounting Bolt Torque Procedure..........................................748 HEATING, VENTILATION, AIR CONDITIONING..........................................................751 AIR CONDITIONING SYSTEM FLOW................................................................754 Principals..............................................................................754 Chart...................................................................................755 COMPONENTS..................................................................................757 Identification..........................................................................757 SAFETY......................................................................................761 Safety Equipment........................................................................761 REGULAR MAINTENANCE.........................................................................763 Filter Elements Removal And Installation................................................763 Compressor Drive Belt Inspection........................................................764 Cleaning The Condenser..................................................................764 BASIC TROUBLESHOOTING.......................................................................767 Poor A/C Performance....................................................................767 Cleaning The A/C Evaporator Coil & Heater Coil..........................................767 Receiver / Drier Sight Glass Inspection.................................................770 Compressor Drive Belt Inspection:.......................................................771 Checking The Electrical System..........................................................771 Engine Coolant Bypassing The Heater Valve...............................................779 Heater Valve Not Opening Or Closing.....................................................779 GENERAL AIR CONDITIONING SERVICE GUIDELINES.................................................781 Compressor Oil..........................................................................781 Compressor Oil Check....................................................................782 Component Replacement And Refrigeration Leaks...........................................783 SYSTEM TROUBLESHOOTING CHART................................................................785 Gauge Pressure Related Troubleshooting..................................................786 TEMPERATURE / PRESSURE......................................................................789 Chart...................................................................................789 AIR CONDITIONING SERVICE....................................................................791 Chart...................................................................................791 SYSTEM CHARGING AND RECLAMATION.............................................................793 Reclamation Procedure...................................................................793 Charging Procedure With A Manifold Gauge Set............................................795 Charging Procedure......................................................................796 COMPRESSOR..................................................................................799 Removal And Installation................................................................799 Compressor Clutch Disassembly...........................................................800 CONDENSER...................................................................................805 Removal And Installation................................................................805 RECEIVER / DRIER............................................................................807 Removal And Installation................................................................807 PRESSURE RELIEF VALVE.......................................................................809 Removal And Installation................................................................809 PRESSURE SWITCH.............................................................................811 Removal And Installation................................................................811 THE EVAPORATOR / HEATER UNIT................................................................813 Removal And Installation................................................................813 Disassembly And Assembly................................................................814 THERMOSTAT..................................................................................815 Removal And Installation................................................................815 EXPANSION VALVE.............................................................................817 Removal And Installation................................................................817 EVAPORATOR..................................................................................819 Removal And Installation................................................................819 HEATER COIL.................................................................................821 Removal And Installation With A/C.......................................................821 Removal And Installation Without A/C....................................................822 HEATER / AC FAN.............................................................................825 Removal And Installation................................................................825 Disassembly And Assembly................................................................825 Wire Connector Removal and Installation.................................................827 HEATER VALVE................................................................................829 Removal and Installation................................................................829 Disassembly And Assembly................................................................830 SPECIFICATIONS..................................................................................833 LOADER SPECIFICATIONS (T200)................................................................835 Loader Dimensions.......................................................................835 Performance.............................................................................836 Controls................................................................................836 Engine..................................................................................836 Hydraulic System........................................................................837 Electrical..............................................................................837 Drive System............................................................................838 Capacities..............................................................................838 Tracks..................................................................................838 Ground Pressure.........................................................................838 ENGINE SPECIFICATIONS.......................................................................839 General.................................................................................839 Fuel System.............................................................................839 Valve and Valve Guide and Seat Insert...................................................840 Piston and Rings........................................................................841 Connecting Rod..........................................................................841 Cylinder Head and Block.................................................................842 Crankshaft and Main Bearings............................................................842 Camshaft and Bearings...................................................................842 Oil Pump................................................................................842 LOADER TORQUE...............................................................................843 Specifications..........................................................................843 TORQUE SPECIFICATIONS FOR BOLTS.............................................................847 Torque For General SAE Bolts............................................................847 Torque For General Metric Bolts.........................................................848 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................849 O-ring Face Seal Connection.............................................................849 Straight Thread O-ring Fitting..........................................................849 Tubelines And Hoses.....................................................................849 Flare Fitting...........................................................................850 O-ring Flare Fitting....................................................................851 Port Seal Fitting.......................................................................853 HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS..................................................855 Specifications..........................................................................855 CONVERSIONS.................................................................................857 Decimal And Millimeter Equivalents......................................................857 U.S. To Metric Conversion Chart.........................................................857 SMR.............................................................................................859 T200-1......................................................................................859 T200-2......................................................................................861 T200-3......................................................................................863 T200-4......................................................................................865 T200-5......................................................................................867 T200-6......................................................................................869
Questions? Email us: [email protected]
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
S.V
