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Bobcat T300 Compact Track Loader Service Manual 6904168 (3-09) – PDF DOWNLOAD
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Bobcat T300 Compact Track Loader Service Manual 6904168 (3-09) – PDF DOWNLOAD
S/N 532011001 & Above
S/N 532111001 & Above
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Description
Bobcat T300 Compact Track Loader Service Manual 6904168 (3-09) – PDF DOWNLOAD
FILE DETAILS:
Bobcat T300 Compact Track Loader Service Manual 6904168 (3-09) – PDF DOWNLOAD
Language : English
Pages : 949
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T300 Compact Track Loader Service Manual 6904168 (3-09) – PDF DOWNLOAD
S/N 532011001 & Above
S/N 532111001 & 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.
TABLE OF CONTENTS:
Bobcat T300 Compact Track Loader Service Manual 6904168 (3-09) – 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 LOADER IDENTIFICATION................................................................................... 17 SAFETY AND MAINTENANCE...................................................................................... 19 LIFTING AND BLOCKING THE LOADER......................................................................... 23 Procedure........................................................................................... 23 LIFT ARM SUPPORT DEVICE................................................................................. 25 Installing.......................................................................................... 25 Removing............................................................................................ 26 OPERATOR CAB............................................................................................ 27 Description......................................................................................... 27 Raising............................................................................................. 27 Lowering............................................................................................ 29 Cab Door Sensor..................................................................................... 30 Special Applications Kit Inspection And Maintenance................................................. 30 TRANSPORTING LOADER ON A TRAILER........................................................................ 31 Loading And Unloading............................................................................... 31 Fastening........................................................................................... 31 TOWING THE LOADER....................................................................................... 33 Procedure........................................................................................... 33 REMOTE START TOOL KIT-MEL1563........................................................................... 35 Remote Start Tool - MEL1563......................................................................... 35 Service Tool Harness Control - MEL1565.............................................................. 36 Service Tool Harness Communicator - MEL1566......................................................... 37 Remote Start Procedure.............................................................................. 38 REMOTE START TOOL (SERVICE TOOL) KIT - 6689779.......................................................... 41 Description......................................................................................... 41 Remote Start Tool (Service Tool) - 6689778.......................................................... 42 Loader Service Tool Harness - 6689747............................................................... 43 Computer Service Tool Harness - 6689746............................................................. 44 Remote Start Procedure.............................................................................. 45 SERVICE SCHEDULE........................................................................................ 49 Chart............................................................................................... 49 AIR CLEANER SERVICE..................................................................................... 51 Replacing Filter Elements........................................................................... 51 ENGINE COOLING SYSTEM................................................................................... 53 Cleaning............................................................................................ 53 Checking Level...................................................................................... 54 Removing And Replacing Coolant...................................................................... 54 FUEL SYSTEM............................................................................................. 55 Fuel Specifications................................................................................. 55 Biodiesel Blend Fuel................................................................................ 55 Filling The Fuel Tank............................................................................... 56 Fuel Filter......................................................................................... 56 Removing Air From The Fuel System................................................................... 57 ENGINE LUBRICATION SYSTEM............................................................................... 59 Checking And Adding Engine Oil...................................................................... 59 Engine Oil Chart.................................................................................... 59 Removing And Replacing Oil And Filter............................................................... 60 HYDRAULIC / HYDROSTATIC SYSTEM.......................................................................... 61 Checking And Adding Fluid........................................................................... 61 Hydraulic / Hydrostatic Fluid Chart................................................................. 61 Removing And Replacing Hydraulic Fluid.............................................................. 62 Removing And Replacing Hydraulic / Hydrostatic Filter............................................... 63 Removing And Replacing Case Drain Filters........................................................... 64 Removing And Replacing Hydraulic Charge Filter...................................................... 65 Breather Cap........................................................................................ 66 BOB-TACH (HAND LEVER)................................................................................... 67 Inspection And Maintenance.......................................................................... 67 BOB-TACH (POWER)........................................................................................ 69 Inspection And Maintenance.......................................................................... 69 LUBRICATING THE LOADER.................................................................................. 71 Lubrication Locations............................................................................... 71 SPARK ARRESTOR MUFFLER.................................................................................. 73 Cleaning Procedure.................................................................................. 73 PIVOT PINS.............................................................................................. 75 Inspection And Maintenance.......................................................................... 75 LOADER STORAGE AND RETURN TO SERVICE.................................................................... 77 Storage............................................................................................. 77 Return to Service................................................................................... 77 STOPPING THE ENGINE AND LEAVING THE LOADER.............................................................. 79 Procedure........................................................................................... 79 Emergency Exit...................................................................................... 80 HYDRAULIC SYSTEM............................................................................................ 81 HYDRAULIC / HYDROSTATIC SCHEMATICS...................................................................... 87 HYDRAULIC SYSTEM INFORMATION............................................................................103 Glossary Of Hydraulic / Hydrostatic Symbols.........................................................103 Troubleshooting.....................................................................................107 CYLINDER (LIFT).........................................................................................109 Testing.............................................................................................109 Removal And Installation............................................................................110 Parts Identification................................................................................112 Disassembly.........................................................................................113 Assembly............................................................................................115 CYLINDER (TILT).........................................................................................117 Testing.............................................................................................117 Removal And Installation............................................................................118 Base End Pivot Pin Removal And Installation.........................................................120 Parts Identification................................................................................121 Disassembly.........................................................................................122 Assembly............................................................................................124 CYLINDER (BOB-TACH).....................................................................................127 Testing.............................................................................................127 Removal And Installation............................................................................128 Parts Identification................................................................................129 Disassembly.........................................................................................130 Assembly............................................................................................131 MAIN RELIEF VALVE.......................................................................................135 Description.........................................................................................135 Testing.............................................................................................135 Adjusting...........................................................................................137 Removal And Installation............................................................................138 HYDRAULIC CONTROL VALVE (STANDARD)......................................................................139 Description.........................................................................................139 Removal And Installation............................................................................140 Identification Chart................................................................................144 Mount Bracket Removal And Installation..............................................................145 Lift Load Check Valve Removal And Installation......................................................145 Load Check Valve Removal And Installation (Tilt & Auxiliary)........................................146 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)......................................146 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End).......................147 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End).......................148 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)........................148 Port Relief Valve Removal And Installation..........................................................149 Plug Removal And Installation.......................................................................150 Rubber Boot Removal and Installation................................................................151 End Cap Block Removal and Installation..............................................................152 Lift Spool And Detent Removal And Installation......................................................153 Tilt Spool Removal And Installation.................................................................163 Auxiliary Spool Removal And Installation............................................................165 Auxiliary Solenoid Removal And Installation.........................................................167 Solenoid Removal And Installation...................................................................168 Lock Valve Removal And Installation.................................................................169 Lift Arm Bypass Orifice Removal And Installation....................................................171 Main Relief Valve Removal And Installation..........................................................171 Check Valve Removal And Installation................................................................172 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)..................................................................173 Description.........................................................................................173 Removal And Installation............................................................................174 Actuator Removal And Installation (In Loader).......................................................178 Actuator Removal And Installation (Out of Loader)...................................................180 Identification Chart................................................................................183 Mount Bracket Removal And Installation..............................................................184 Lift Load Check Valve Removal And Installation......................................................184 Load Check Valve Removal And Installation (Tilt & Auxiliary)........................................185 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)......................................185 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End).......................186 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End).......................187 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)........................187 Port Relief Valve Removal And Installation..........................................................188 Plug Removal And Installation.......................................................................189 End Cap Block Removal And Installation..............................................................190 Lift Spool And Detent Removal And Installation......................................................191 Tilt Spool Removal And Installation.................................................................196 Auxiliary Spool Removal And Installation............................................................198 Auxiliary Solenoid Removal And Installation.........................................................200 Solenoid Removal And Installation...................................................................201 Lock Valve Removal And Installation.................................................................202 Lift Arm Bypass Orifice Removal And Installation....................................................204 Main Relief Valve Removal And Installation..........................................................204 Check Valve Removal And Installation................................................................205 LIFT ARM BYPASS CONTROL VALVE...........................................................................207 Description.........................................................................................207 Testing.............................................................................................207 Removal And Installation............................................................................207 Disassembly And Assembly............................................................................208 HYDRAULIC PUMP (STANDARD)...............................................................................209 Description.........................................................................................209 Pump Test At Quick Couplers.........................................................................209 Direct Pump Test (Standard Section).................................................................210 Direct Pump Test (Charge Section)...................................................................212 Removal And Installation............................................................................216 Hydraulic Pump Start Up.............................................................................218 Parts Identification................................................................................220 Disassembly And Assembly............................................................................221 HYDRAULIC PUMP (STANDARD) (HIGH FLOW)...................................................................223 Description.........................................................................................223 Pump Test At Quick Couplers.........................................................................223 Direct Pump Test (Standard Section).................................................................224 Direct Pump Test (Charge Section)...................................................................226 Direct Pump Test (High Flow Section)................................................................230 High Flow Relief Valve Adjustment...................................................................232 High Flow Relief Valve Removal And Installation.....................................................234 Solenoid Removal And Installation...................................................................235 Removal And Installation............................................................................236 Hydraulic Pump Start Up.............................................................................238 Parts Identification................................................................................240 Disassembly And Assembly............................................................................241 HYDRAULIC PUMP (SJC)....................................................................................243 Description.........................................................................................243 Pump Test At Quick Couplers.........................................................................243 Direct Pump Test (Standard Section).................................................................244 Direct Pump Test (Charge Section)...................................................................246 Removal And Installation............................................................................250 Hydraulic Pump Start Up.............................................................................252 Parts Identification................................................................................254 Disassembly And Assembly............................................................................255 HYDRAULIC PUMP (SJC) (HIGH FLOW)........................................................................257 Description.........................................................................................257 Pump Test At Quick Couplers.........................................................................258 Direct Pump Test (Standard Section).................................................................259 Direct Pump Test (Charge Section)...................................................................261 Direct Pump Test (High Flow Section)................................................................265 High Flow Relief Valve Adjustment...................................................................267 High Flow Relief Valve Removal And Installation.....................................................269 Solenoid Removal And Installation...................................................................270 Removal And Installation............................................................................271 Hydraulic Pump Start Up.............................................................................273 Parts Identification................................................................................274 Disassembly And Assembly............................................................................275 HYDRAULIC/HYDROSTATIC FILTERS...........................................................................277 Description.........................................................................................277 Housing Removal And Installation....................................................................278 Charge Filter Housing Removal And Installation......................................................280 HYDRAULIC FLUID RESERVOIR...............................................................................281 Description.........................................................................................281 Removal And Installation............................................................................281 Hydraulic Fluid Screen..............................................................................284 OIL COOLER..............................................................................................285 Description.........................................................................................285 Removal And Installation............................................................................285 BUCKET POSITION VALVE...................................................................................287 Description.........................................................................................287 Solenoid Removal And Installation...................................................................288 Solenoid Testing....................................................................................288 Removal And Installation............................................................................289 Disassembly And Assembly............................................................................289 REAR AUXILIARY DIVERTER VALVE...........................................................................291 Description.........................................................................................291 Solenoid Testing....................................................................................291 Removal And Installation............................................................................292 Disassembly And Assembly............................................................................294 BOB-TACH (POWER) BLOCK..................................................................................301 Description.........................................................................................301 Removal And Installation............................................................................301 Disassembly And Assembly............................................................................303 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.................................................................307 Description.........................................................................................307 Removal and Installation............................................................................307 Disassembly And Assembly............................................................................308 HYDROSTATIC SYSTEM..........................................................................................311 HYDROSTATIC SYSTEM INFORMATION..........................................................................313 Troubleshooting.....................................................................................313 Description.........................................................................................314 HYDROSTATIC MOTOR.......................................................................................315 Description.........................................................................................315 Removing And Replacing Oil..........................................................................315 Removal And Installation............................................................................316 Parts Identification................................................................................318 Disassembly And Assembly............................................................................320 CHARGE PRESSURE.........................................................................................333 Description.........................................................................................333 Testing.............................................................................................333 Sender Removal And Installation.....................................................................335 Adjusting...........................................................................................336 HYDROSTATIC PUMP........................................................................................339 Description.........................................................................................339 Removal And Installation............................................................................339 Hydrostatic Pump Start Up...........................................................................340 Replenishing / High Pressure Relief Valve Removal And Installation..................................341 Parts Identification (Left Half)....................................................................342 Parts Identification (Right Half)...................................................................343 Disassembly.........................................................................................344 Assembly............................................................................................351 HYDROSTATIC PUMP (SJC)..................................................................................357 Description.........................................................................................357 Hydraulic Controller Removal And Installation.......................................................358 Removal And Installation............................................................................360 Hydrostatic Pump Start Up...........................................................................362 Parts Identification................................................................................363 High Pressure Relief And Bypass Valve...............................................................364 Charge Relief Valve.................................................................................365 Disassembly And Assembly............................................................................366 Mechanical Neutral Adjustment.......................................................................383 Hydraulic Controller Neutral Adjustment.............................................................386 DRIVE BELT..............................................................................................389 Description.........................................................................................389 Drive Belt Shield Removal And Installation..........................................................389 Adjusting...........................................................................................390 Belt Adjustment.....................................................................................390 Drive Belt Removal And Installation.................................................................390 Tensioner Pulley Removal And Installation...........................................................391 Disassembly And Assembly............................................................................392 Tensioner Pulley Tension Spring Removal And Installation............................................393 CASE DRAIN FILTER.......................................................................................395 Description.........................................................................................395 Disassembly And Assembly............................................................................395 DRIVE SYSTEM................................................................................................397 BRAKE...................................................................................................399 Description.........................................................................................399 Block Removal And Installation......................................................................399 Block Disassembly And Assembly......................................................................400 TRACK CARRIAGE COMPONENTS...............................................................................401 Description.........................................................................................401 Checking Tension....................................................................................402 Adjusting Tension...................................................................................403 Track Removal And Installation......................................................................404 Idler (Front) Removal And Installation..............................................................406 Idler (Rear) Removal And Installation...............................................................409 Roller Removal And Installation.....................................................................409 Sprocket Removal And Installation...................................................................410 Carriage Removal And Installation...................................................................411 Track Damage Identification.........................................................................412 MAIN FRAME..................................................................................................423 SEAT BAR................................................................................................427 Description.........................................................................................427 Removal And Installation............................................................................427 Disassembly And Assembly............................................................................429 Compression Spring Disassembly And Assembly.........................................................430 OPERATOR CAB............................................................................................431 Gas Cylinder Removal And Installation...............................................................431 Gas Cylinder Bracket Disassembly And Assembly.......................................................433 Removal And Installation............................................................................434 OPERATOR SEAT (SUSPENSION)..............................................................................437 Removal And Installation............................................................................437 Slide Rail Removal And Installation.................................................................438 Seat Belt Removal And Installation..................................................................438 Lower Cushion Removal And Installation..............................................................439 Back Cushion Removal And Installation...............................................................440 Shock Removal And Installation......................................................................440 3-Point Seat Belt Removal And Installation..........................................................441 BOB-TACH (HAND LEVER)...................................................................................443 Description.........................................................................................443 Removal And Installation............................................................................443 Lever And Wedge Disassembly And Assembly............................................................445 Pivot Pin Bushing And Seal Removal And Installation.................................................446 BOB-TACH (POWER - OPTION)...............................................................................447 Description.........................................................................................447 Removal And Installation............................................................................447 Lever And Wedge Disassembly And Assembly............................................................449 Pivot Pin Bushing And Seal Removal And Installation.................................................451 LIFT ARMS...............................................................................................453 Stabilizer Bar Removal And Installation.............................................................453 Link Removal And Installation.......................................................................454 Removal And Installation............................................................................455 REAR GRILL..............................................................................................459 Removal And Installation............................................................................459 REAR DOOR...............................................................................................461 Removal And Installation............................................................................461 Striker Removal And Installation....................................................................462 Striker Disassembly And Assembly....................................................................462 Striker (Adjusting).................................................................................462 Latch Removal And Installation......................................................................463 FUEL TANK...............................................................................................465 Removal And Installation............................................................................465 Fuel Level Sender Removal And Installation..........................................................467 Fuel Fill Screen Removal And Installation...........................................................467 CONTROL PEDALS AND LINKAGES.............................................................................469 Description.........................................................................................469 Pedal Removal And Installation......................................................................470 Linkage Removal And Installation....................................................................471 Pedal (Adjusting)...................................................................................472 CONTROL PEDALS (ACS)....................................................................................473 Description.........................................................................................473 Foot Sensor Removal And Installation................................................................473 Foot Pedal Removal And Installation.................................................................474 Foot Pedal Linkage Disassembly And Assembly.........................................................474 CONTROL PANEL (S/N 532016717 & BELOW AND 532111676 & BELOW).............................................475 Description.........................................................................................475 Removal And Installation............................................................................476 Shock Removal And Installation......................................................................478 Shaft Removal And Installation......................................................................478 Shaft Disassembly And Assembly......................................................................479 Linkage Removal And Installation....................................................................480 Pintle Arm Disassembly and Assembly.................................................................484 Linkage Neutral (Adjusting).........................................................................485 Linkage Travel (Adjusting)..........................................................................489 CONTROL PANEL (S/N 532016718 & ABOVE AND 532111677 & ABOVE).............................................493 Description.........................................................................................493 Removal And Installation............................................................................494 Shock Removal And Installation......................................................................496 Shaft Removal And Installation......................................................................497 Linkage Removal And Installation....................................................................498 Pintle Arm Disassembly and Assembly.................................................................502 Linkage Neutral (Adjusting).........................................................................503 Linkage Travel (Adjusting)..........................................................................507 CONTROL PANEL (S/N 532016717 & BELOW AND 532111676 & BELOW) (SJC).......................................511 Description.........................................................................................511 Removal And Installation............................................................................512 CONTROL PANEL (S/N 532016718 & ABOVE AND 532111677 & ABOVE) (SJC).......................................515 Description.........................................................................................515 Removal And Installation............................................................................516 CONTROL HANDLE / LEVER..................................................................................519 Description.........................................................................................519 Lever Removal And Installation......................................................................519 Boot Removal And Installation.......................................................................519 CONTROL HANDLE / LEVER (ACS)............................................................................521 Description.........................................................................................521 Handle Sensor Removal And Installation..............................................................521 Handle Removal And Installation.....................................................................524 Handle Disassembly And Assembly.....................................................................525 Lever Removal And Installation......................................................................526 Boot Removal And Installation.......................................................................527 JOYSTICK CONTROL........................................................................................529 Description.........................................................................................529 Testing.............................................................................................530 Removal And Installation (S/N 532011001-532013987, S/N 532111001 - 532111169).......................531 Removal And Installation (S/N 532013988 & Above, S/ N 532111170 & Above)............................532 Boot Removal And Installation (S/N 532011001- 532013987, S/N 532111001 - 532111169).................533 Joystick Mount Removal And Installation (S/N 532011001-532013987, S/N 532111001 - 532111169)........533 Joystick Mount Removal And Installation (S/N 532013988 & Above, S/N 532111170 & Above)..............534 ACCESS PANEL (INSIDE)...................................................................................535 Removal And Installation (Left).....................................................................535 Removal And Installation (Right)....................................................................535 ACCESS PANEL (INSIDE)...................................................................................537 Removal And Installation (Left).....................................................................537 Removal And Installation (Right)....................................................................538 WINDOW (REAR)...........................................................................................541 Removal.............................................................................................541 Installation........................................................................................541 WINDOW (TOP)............................................................................................543 Removal And Installation............................................................................543 WINDOW (SIDE)...........................................................................................545 Removal And Installation............................................................................545 WINDOW (FRONT DOOR).....................................................................................547 Removal (Standard Window)...........................................................................547 Installation (Standard Window)......................................................................548 Removal And Installation (Special Applications Window)..............................................550 CAB DOOR................................................................................................551 Description.........................................................................................551 Removal And Installation............................................................................551 Aligning............................................................................................552 Adjusting...........................................................................................553 Checking Operation..................................................................................553 ELECTRICAL SYSTEM & ANALYSIS................................................................................555 ELECTRICAL SCHEMATICS...................................................................................559 ELECTRICAL SYSTEM INFORMATION...........................................................................572 Glossary Of Electrical Symbols......................................................................572 Cab Harness Connectors..............................................................................575 Mainframe Harness Connectors........................................................................576 Description.........................................................................................577 Troubleshooting.....................................................................................579 Fuse And Relay Location / Identification............................................................580 Solenoid Testing....................................................................................581 BATTERY.................................................................................................582 Servicing...........................................................................................582 Using A Booster Battery (Jump Starting).............................................................582 Removal And Installation............................................................................584 ALTERNATOR..............................................................................................586 Belt Adjustment.....................................................................................586 Charging System Inspection..........................................................................587 Alternator Voltage Testing..........................................................................588 Low Voltage Testing.................................................................................588 High Voltage Testing................................................................................589 Removal And Installation............................................................................590 Parts Identification................................................................................591 STARTER.................................................................................................592 Testing.............................................................................................592 Removal And Installation............................................................................593 Parts Identification................................................................................594 INSTRUMENT PANELS.......................................................................................596 Left Panel..........................................................................................596 Right Panel (Key Switch)............................................................................597 Right Panel (Keyless)...............................................................................598 Side And Front Panels...............................................................................600 Removal And Installation (Left And Right)...........................................................601 Bulb Removal And Installation (Left Only)...........................................................604 Key Switch Removal And Installation.................................................................605 Alarm Removal And Installation......................................................................606 Front Panel Removal And Installation................................................................606 LIGHTS..................................................................................................608 Front Removal And Installation......................................................................608 Rear Removal And Installation.......................................................................609 Cab Light Removal And Installation..................................................................609 BOBCAT CONTROLLER (MAIN)................................................................................610 Description.........................................................................................610 Connector Identification............................................................................611 Removal And Installation............................................................................613 BOBCAT CONTROLLER (ACS).................................................................................614 Description.........................................................................................614 Connector And Wire Identification...................................................................615 Removal And Installation............................................................................616 BOBCAT CONTROLLER (SJC) (DRIVE).........................................................................618 Description.........................................................................................618 Connector Identification............................................................................619 Removal And Installation............................................................................621 SPEED SENSORS (SJC).....................................................................................622 Description.........................................................................................622 Testing.............................................................................................622 Removal and Installation............................................................................624 DIAGNOSTIC SERVICE CODES................................................................................626 Description.........................................................................................626 Service Codes List..................................................................................627 BOBCAT INTERLOCK CONTROL SYSTEM (BICS)..................................................................634 Description.........................................................................................634 Inspecting The BICS Controller (Engine STOPPED - Key ON)............................................635 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)................635 Inspecting The Seat Bar Sensor (Engine RUNNING).....................................................635 Inspecting The Traction Lock (Engine RUNNING).......................................................635 Inspecting The Lift Arm Bypass Control..............................................................635 Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)....................................635 Troubleshooting.....................................................................................636 Troubleshooting Chart...............................................................................637 SEAT BAR SENSOR.........................................................................................638 Description.........................................................................................638 Troubleshooting.....................................................................................639 Testing.............................................................................................640 Removal And Installation............................................................................641 Bobcat Interlock Control System (BICS) Circuit Test.................................................642 TRACTION LOCK...........................................................................................644 Description.........................................................................................644 Troubleshooting.....................................................................................645 Inspecting..........................................................................................646 Parking Brake Solenoid Removal And Installation.....................................................647 CONTROL SYSTEM (ACS)....................................................................................648 Description.........................................................................................648 Troubleshooting Chart...............................................................................649 Handle Sensor Connector Disassembly And Assembly....................................................650 Switch Handle Removal...............................................................................651 Switch Handle Installation..........................................................................653 Actuator Connector Disassembly And Assembly.........................................................656 Handle Lock Solenoid Removal And Installation.......................................................657 Handle Lock Solenoid Disassembly And Assembly.......................................................658 Foot Sensor Disassembly And Assembly................................................................658 Foot Lock Solenoid Removal And Installation.........................................................659 ELECTRICAL / HYDRAULIC CONTROLS.........................................................................660 Identification Chart................................................................................660 ELECTRICAL / HYDRAULIC CONTROLS (SJC)...................................................................662 Identification Chart................................................................................662 SERVICE PC (LAPTOP COMPUTER)............................................................................666 Connecting Remote Start Tool........................................................................666 Connecting Remote Start Tool (Service Tool).........................................................666 CALIBRATION.............................................................................................668 Description.........................................................................................668 Actuator Testing....................................................................................668 Lift And Tilt Calibration (ACS).....................................................................670 Lift And Tilt Calibration (SJC).....................................................................672 Hydrostatic Pump Calibration (SJC)..................................................................674 STEERING DRIFT COMPENSATION.............................................................................680 Description.........................................................................................680 Selecting And Adjusting.............................................................................680 Exiting And Saving..................................................................................681 FLYWHEEL RPM SENSOR.....................................................................................682 Description.........................................................................................682 Adjustment..........................................................................................682 CONTROL PANEL SETUP.....................................................................................684 Right Panel Setup (Keyless).........................................................................684 Attachment Control Information (Keyless)............................................................685 PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START).........................................................686 Password Description................................................................................686 Changing The Owner Password.........................................................................686 Changing The User Passwords.........................................................................687 Password Lockout Feature............................................................................687 MAINTENANCE CLOCK.......................................................................................688 Description.........................................................................................688 Setup...............................................................................................689 Reset...............................................................................................693 BACK-UP ALARM SYSTEM....................................................................................694 Description.........................................................................................694 Inspecting..........................................................................................694 Adjusting Switch Position...........................................................................695 Troubleshooting (Standard And ACS)..................................................................696 Troubleshooting (Joystick)..........................................................................697 Alarm Removal And Installation......................................................................698 Switch Removal And Installation.....................................................................698 ENGINE SERVICE..............................................................................................700 ENGINE INFORMATION......................................................................................704 Description.........................................................................................704 Specifications......................................................................................705 Torque Values.......................................................................................709 Troubleshooting.....................................................................................710 Engine Removal And Installation.....................................................................712 Engine Mount Replacement............................................................................721 Compression -Checking...............................................................................722 ENGINE SPEED CONTROL....................................................................................724 Removal And Installation............................................................................724 Cable Removal And Installation......................................................................725 ENGINE SPEED CONTROL (SJC)..............................................................................726 Removal And Installation............................................................................726 Disassembly And Assembly............................................................................728 Speed Control Cable Removal And Installation........................................................729 MUFFLER.................................................................................................730 Removal And Installation............................................................................730 AIR CLEANER.............................................................................................732 Housing Removal And Installation....................................................................732 ENGINE COOLING SYSTEM...................................................................................734 Radiator Removal And Installation (S/N 532015065 & Below, 532111566 & Below)........................734 Radiator Removal And Installation (S/N 532015066 & Above, 532111567 & Above)........................736 Radiator Mount Removal And Installation.............................................................738 Hydraulic Fan Motor Description (S/N 532015065 & Below, 532111566 & Below)..........................739 Blower Housing Removal And Installation (S/N 532015065 & Below, 532111566 & Below)..................739 Fan Removal And Installation (S/N 532015065 & Below, 532111566 & Below).............................741 Hydraulic Fan Motor Removal And Installation (S/N 532015065 & Below, 532111566 & Below).............742 Hydraulic Fan Motor Disassembly And Assembly (S/ N 532015065 & Below, 532111566 & Below)............742 Hydraulic Fan Motor Description (S/N 532015066 - 532040000, 532111567 - 532140000)..................743 Axial Fan Housing Removal And Installation (S/N 532015066 - 532040000, 532111567 - 532140000))......743 Axial Fan Removal And Installation (S/N 532015066 - 532040000, 532111567 - 532140000)...............745 Hydraulic Fan Motor Removal And Installation (S/N 532015066 - 532040000, 532111567 - 532140000).....747 Hydraulic Fan Motor Disassembly And Assembly (S/ N 532015066 - 532040000, 532111567 - 532140000)....747 Hydraulic Fan Motor Description (S/N 532040001 & Above, 532140001 & Above)..........................748 Axial Fan Housing Removal And Installation (S/N 532040001 & Above, 532140001 & Above)...............748 Axial Fan Removal And Installation (S/N 532040001 & Above, 532140001 & Above).......................751 Hydraulic Fan Motor Removal And Installation (S/N 532040001 & Above, 532140001 & Above).............752 Hydraulic Fan Motor Disassembly And Assembly (S/ N 532040001 & Above, 532140001 & Above)............753 Water Pump Removal And Installation.................................................................754 Water Pump Disassembly And Assembly.................................................................755 Thermostat Housing Removal And Installation.........................................................755 LUBRICATION SYSTEM......................................................................................758 Oil Pan Removal And Installation....................................................................758 Oil Pump Removal And Installation...................................................................759 Oil Pump Inspection.................................................................................759 Oil Filter Cooler Removal And Installation..........................................................762 Engine Oil Pressure - Testing.......................................................................763 FUEL SYSTEM.............................................................................................764 Fuel Camshaft Removal And Installation..............................................................764 Injection Pump Governor Housing Removal And Installation............................................766 Injection Pump Governor Housing Disassembly And Assembly............................................768 Injection Pump Governor Housing Disassembly And Assembly (Cont’d)...................................769 Fuel Shutoff Solenoid - Checking....................................................................770 Fuel Shutoff Solenoid - Removal And Installation....................................................770 Fuel Injection Pump Removal And Installation........................................................771 Fuel Injection Pump Housing Removal.................................................................779 Fuel Injection Pump Housing Installation............................................................783 Injection Pump Timing...............................................................................786 Fuel Injector Removal and Installation..............................................................789 Fuel Injector Nozzle Pressure - Checking............................................................790 Nozzle Spraying Condition...........................................................................791 Valve Seat Tightness................................................................................791 CYLINDER HEAD...........................................................................................792 Intake Air Heater - Testing.........................................................................792 Intake Air Heater Removal And Installation..........................................................792 Valve Clearance Adjustment..........................................................................793 Valve Timing - Checking.............................................................................794 Cylinder Head Removal And Installation..............................................................795 Cylinder Head Disassembly And Assembly..............................................................798 Cylinder Head - Servicing...........................................................................798 Cylinder Head Top Clearance.........................................................................799 Valve Guide - Checking..............................................................................800 Reconditioning The Valve And Valve Seat.............................................................802 Valve Spring........................................................................................804 Valve Tappets.......................................................................................805 Rocker Arm And Shaft - Checking.....................................................................806 CRANKSHAFT AND PISTONS..................................................................................808 Piston And Connecting Rod Removal And Installation..................................................808 Piston And Connecting Rod - Servicing...............................................................810 Cylinder Bore Checking..............................................................................815 Connecting Rod Alignment............................................................................816 Crankshaft Gear Removal And Installation............................................................816 Crankshaft And Bearings Removal and Installation....................................................817 Crankshaft And Bearings - Servicing.................................................................821 CAMSHAFT AND TIMING GEArS...............................................................................828 Timing Gearcase Cover Removal And Installation......................................................828 Timing Gears Backlash - Checking....................................................................829 Camshaft - Servicing................................................................................830 Idle Gear And Shaft Removal And Installation........................................................832 Idler Gear And Shaft - Servicing....................................................................833 TURBOCHARGER............................................................................................836 Description.........................................................................................836 Testing.............................................................................................836 Removal And Installation............................................................................837 FLYWHEEL AND HOUSING....................................................................................838 Flywheel Removal And Installation...................................................................838 Ring Gear Removal And Installation..................................................................838 Housing Removal And Installation....................................................................839 HEATING, VENTILATION, AIR CONDITIONING......................................................................840 AIR CONDITIONING SYSTEM FLOW............................................................................843 Description.........................................................................................843 Chart...............................................................................................844 Components..........................................................................................845 Safety Equipment....................................................................................848 REGULAR MAINTENANCE.....................................................................................850 Filter Elements Removal And Installation............................................................850 Compressor Drive Belt Inspection....................................................................851 Condenser...........................................................................................852 Air Conditioning Service Chart......................................................................853 A/C Evaporator Coil & Heater Coil...................................................................854 TROUBLESHOOTING.........................................................................................856 Blower Motor Does Not Operate.......................................................................856 Blower Motor Operates Normally, But Air Flow Is Insufficient........................................856 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..........................856 The Compressor Does Not Operate At All, Or Operates Improperly......................................856 Gauge Pressure Related Troubleshooting..............................................................857 Troubleshooting Tree................................................................................859 Temperature / Pressure Chart........................................................................863 Poor A/C Performance................................................................................865 HVAC Repair And Leaks...............................................................................866 Electrical System...................................................................................867 Engine Coolant Bypassing The Heater Valve...........................................................874 Heater Valve Not Opening Or Closing.................................................................875 SYSTEM CHARGING AND RECLAMATION.........................................................................876 Refrigerant Identification..........................................................................876 Reclamation And Charging With Recovery / Charging Unit..............................................877 Charging With A Manifold Gauge Set..................................................................879 COMPRESSOR..............................................................................................882 Belt Adjustment.....................................................................................882 Removal And Installation............................................................................882 Oil.................................................................................................883 Oil Check...........................................................................................884 Clutch Disassembly And Assembly.....................................................................885 CONDENSER...............................................................................................890 Removal And Installation............................................................................890 RECEIVER / DRIER........................................................................................892 Receiver / Drier Removal And Installation...........................................................892 Pressure Relief Valve Removal And Installation......................................................893 Pressure Switch Removal And Installation............................................................893 Schraeder Valve Removal And Installation............................................................894 EVAPORATOR / HEATER UNIT................................................................................896 Removal And Installation............................................................................896 THERMOSTAT..............................................................................................898 Removal And Installation............................................................................898 EXPANSION VALVE.........................................................................................900 Removal And Installation............................................................................900 EVAPORATOR..............................................................................................902 Removal And Installation............................................................................902 HEATER COIL.............................................................................................904 Removal And Installation With A/C...................................................................904 Removal And Installation Without A/C................................................................906 BLOWER FAN..............................................................................................908 Removal And Installation............................................................................908 Disassembly And Assembly............................................................................909 Connector Identification............................................................................911 HEATER VALVE............................................................................................912 Removal and Installation............................................................................912 Disassembly And Assembly............................................................................913 SPECIFICATIONS..............................................................................................914 (T300) LOADER SPECIFICATIONS............................................................................916 Dimensions..........................................................................................916 Performance.........................................................................................917 Controls............................................................................................917 Engine..............................................................................................917 Hydraulic System....................................................................................918 Electrical..........................................................................................919 Drive System........................................................................................919 Capacities..........................................................................................919 Tracks..............................................................................................919 Ground Pressure.....................................................................................919 TORQUE SPECIFICATIONS FOR BOLTS.........................................................................920 Torque For General SAE Bolts........................................................................920 Torque For General Metric Bolts.....................................................................921 HYDRAULIC CONNECTION SPECIFICATIONS.....................................................................922 O-ring Face Seal Connection.........................................................................922 Straight Thread O-ring Fitting......................................................................923 Tubelines And Hoses.................................................................................923 Flare Fitting.......................................................................................924 Port Seal Fitting...................................................................................925 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS............................................................926 Specifications......................................................................................926 CONVERSIONS.............................................................................................928 Decimal And Millimeter Equivalents..................................................................928 U.S. To Metric Conversion Chart.....................................................................928 SERVICE MANUAL REVISION.....................................................................................930 Revision No: T300 - 1...................................................................................930 Revision No: T300 - 2...................................................................................932 Revision No: T300 - 3...................................................................................934 Revision No: T300 - 4...................................................................................936 Revision No: T300 - 5...................................................................................938 Revision No: T300 - 6...................................................................................940 Revision No: T300 - 7...................................................................................942 Revision No: T300 - 8...................................................................................944 Revision No: T300 - 9...................................................................................946 Revision No: T300 - 10..................................................................................948
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