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Bobcat T300 Compact Track Loader Service Manual 6986683 (3-09) – PDF DOWNLOAD
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Bobcat T300 Compact Track Loader Service Manual 6986683 (3-09) – PDF DOWNLOAD
S/N A5GU11001 – A5GU19999
S/N A5GV11001 – A5GV19999
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Description
Bobcat T300 Compact Track Loader Service Manual 6986683 (3-09) – PDF DOWNLOAD
FILE DETAILS:
Bobcat T300 Compact Track Loader Service Manual 6986683 (3-09) – PDF DOWNLOAD
Language : English
Pages : 875
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T300 Compact Track Loader Service Manual 6986683 (3-09) – PDF DOWNLOAD
S/N A5GU11001 – A5GU19999
S/N A5GV11001 – A5GV19999
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 6986683 (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............................................................. 21 Procedure............................................................................... 21 LIFT ARM SUPPORT DEVICE..................................................................... 23 Installing.............................................................................. 23 Removing................................................................................ 24 OPERATOR CAB................................................................................ 25 Description............................................................................. 25 Raising................................................................................. 25 Lowering................................................................................ 27 Cab Door Sensor......................................................................... 28 Special Applications Kit Inspection And Maintenance..................................... 28 TRANSPORTING LOADER ON A TRAILER............................................................ 29 Loading And Unloading................................................................... 29 Fastening............................................................................... 29 TOWING THE LOADER........................................................................... 31 Procedure............................................................................... 31 REMOTE START TOOL KIT-MEL1563............................................................... 33 Remote Start Tool - MEL1563............................................................. 33 Service Tool Harness Control - MEL1565.................................................. 34 Service Tool Harness Communicator - MEL1566............................................. 35 Remote Start Procedure.................................................................. 36 REMOTE START TOOL (SERVICE TOOL) KIT - 6689779.............................................. 39 Description............................................................................. 39 Remote Start Tool (Service Tool) - 6689778.............................................. 40 Loader Service Tool Harness - 6689747................................................... 41 Computer Service Tool Harness - 6689746................................................. 42 Remote Start Procedure.................................................................. 43 SERVICE SCHEDULE............................................................................ 47 Chart................................................................................... 47 AIR CLEANER SERVICE......................................................................... 49 Replacing Filter Elements............................................................... 49 ENGINE COOLING SYSTEM....................................................................... 51 Cleaning................................................................................ 51 Checking Level.......................................................................... 52 Removing And Replacing Coolant.......................................................... 52 FUEL SYSTEM................................................................................. 53 Fuel Specifications..................................................................... 53 Biodiesel Blend Fuel.................................................................... 53 Filling The Fuel Tank................................................................... 54 Fuel Filter............................................................................. 54 Removing Air From The Fuel System....................................................... 55 ENGINE LUBRICATION SYSTEM................................................................... 57 Checking And Adding Engine Oil.......................................................... 57 Engine Oil Chart........................................................................ 57 Removing And Replacing Oil And Filter................................................... 58 HYDRAULIC / HYDROSTATIC SYSTEM.............................................................. 59 Checking And Adding Fluid............................................................... 59 Hydraulic / Hydrostatic Fluid Chart..................................................... 59 Removing And Replacing Hydraulic Fluid.................................................. 60 Removing And Replacing Hydraulic / Hydrostatic Filter................................... 61 Removing And Replacing Case Drain Filters............................................... 62 Removing And Replacing Hydraulic Charge Filter.......................................... 63 Breather Cap............................................................................ 64 BOB-TACH (HAND LEVER)....................................................................... 65 Inspection And Maintenance.............................................................. 65 BOB-TACH (POWER)............................................................................ 67 Inspection And Maintenance.............................................................. 67 LUBRICATING THE LOADER...................................................................... 69 Lubrication Locations................................................................... 69 SPARK ARRESTOR MUFFLER...................................................................... 71 Cleaning Procedure...................................................................... 71 PIVOT PINS.................................................................................. 73 Inspection And Maintenance.............................................................. 73 LOADER STORAGE AND RETURN TO SERVICE........................................................ 75 Storage................................................................................. 75 Return to Service....................................................................... 75 STOPPING THE ENGINE AND LEAVING THE LOADER.................................................. 77 Procedure............................................................................... 77 Emergency Exit.......................................................................... 78 HYDRAULIC SYSTEM................................................................................ 79 HYDRAULIC / HYDROSTATIC SCHEMATICS.......................................................... 85 HYDRAULIC SYSTEM INFORMATION................................................................ 93 Glossary Of Hydraulic / Hydrostatic Symbols............................................. 93 Troubleshooting......................................................................... 97 CYLINDER (LIFT)............................................................................. 99 Testing................................................................................. 99 Removal And Installation................................................................100 Parts Identification....................................................................102 Disassembly.............................................................................103 Assembly................................................................................105 CYLINDER (TILT).............................................................................107 Testing.................................................................................107 Removal And Installation................................................................108 Base End Pivot Pin Removal And Installation.............................................110 Parts Identification....................................................................111 Disassembly.............................................................................112 Assembly................................................................................114 CYLINDER (BOB-TACH).........................................................................117 Testing.................................................................................117 Removal And Installation................................................................118 Parts Identification....................................................................119 Disassembly.............................................................................120 Assembly................................................................................121 MAIN RELIEF VALVE...........................................................................125 Description.............................................................................125 Testing.................................................................................125 Adjusting...............................................................................127 Removal And Installation................................................................128 HYDRAULIC CONTROL VALVE (STANDARD)..........................................................129 Description.............................................................................129 Removal And Installation................................................................130 Identification Chart....................................................................134 Mount Bracket Removal And Installation..................................................135 Lift Load Check Valve Removal And Installation..........................................135 Load Check Valve Removal And Installation (Tilt & Auxiliary)............................136 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................136 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........137 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........138 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............138 Port Relief Valve Removal And Installation..............................................139 Plug Removal And Installation...........................................................140 Rubber Boot Removal and Installation....................................................141 End Cap Block Removal and Installation..................................................142 Lift Spool And Detent Removal And Installation..........................................143 Tilt Spool Removal And Installation.....................................................153 Auxiliary Spool Removal And Installation................................................155 Auxiliary Solenoid Removal And Installation.............................................157 Solenoid Removal And Installation.......................................................158 Lock Valve Removal And Installation.....................................................159 Lift Arm Bypass Orifice Removal And Installation........................................161 Main Relief Valve Removal And Installation..............................................161 Check Valve Removal And Installation....................................................162 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)......................................................163 Description.............................................................................163 Removal And Installation................................................................164 Actuator Removal And Installation (In Loader)...........................................168 Actuator Removal And Installation (Out of Loader).......................................170 Identification Chart....................................................................173 Mount Bracket Removal And Installation..................................................174 Lift Load Check Valve Removal And Installation..........................................174 Load Check Valve Removal And Installation (Tilt & Auxiliary)............................175 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................175 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........176 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........177 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............177 Port Relief Valve Removal And Installation..............................................178 Plug Removal And Installation...........................................................179 End Cap Block Removal And Installation..................................................180 Lift Spool And Detent Removal And Installation..........................................181 Tilt Spool Removal And Installation.....................................................186 Auxiliary Spool Removal And Installation................................................188 Auxiliary Solenoid Removal And Installation.............................................190 Solenoid Removal And Installation.......................................................191 Lock Valve Removal And Installation.....................................................192 Lift Arm Bypass Orifice Removal And Installation........................................194 Main Relief Valve Removal And Installation..............................................194 Check Valve Removal And Installation....................................................195 LIFT ARM BYPASS CONTROL VALVE...............................................................197 Description.............................................................................197 Testing.................................................................................197 Removal And Installation................................................................197 Disassembly And Assembly................................................................198 HYDRAULIC PUMP (STANDARD)...................................................................199 Description.............................................................................199 Pump Test At Quick Couplers.............................................................199 Direct Pump Test (Standard Section).....................................................200 Direct Pump Test (Charge Section).......................................................202 Removal And Installation................................................................206 Hydraulic Pump Start Up.................................................................208 Parts Identification....................................................................210 Disassembly And Assembly................................................................211 HYDRAULIC PUMP (STANDARD) (HIGH FLOW).......................................................213 Description.............................................................................213 Pump Test At Quick Couplers.............................................................213 Direct Pump Test (Standard Section).....................................................214 Direct Pump Test (Charge Section).......................................................216 Direct Pump Test (High Flow Section)....................................................220 High Flow Relief Valve Adjustment.......................................................222 High Flow Relief Valve Removal And Installation.........................................224 Solenoid Removal And Installation.......................................................225 Removal And Installation................................................................226 Hydraulic Pump Start Up.................................................................228 Parts Identification....................................................................230 Disassembly And Assembly................................................................231 HYDRAULIC PUMP (SJC)........................................................................233 Description.............................................................................233 Pump Test At Quick Couplers.............................................................233 Direct Pump Test (Standard Section).....................................................234 Direct Pump Test (Charge Section).......................................................236 Removal And Installation................................................................240 Hydraulic Pump Start Up.................................................................242 Parts Identification....................................................................244 Disassembly And Assembly................................................................245 HYDRAULIC PUMP (SJC) (HIGH FLOW)............................................................247 Description.............................................................................247 Pump Test At Quick Couplers.............................................................248 Direct Pump Test (Standard Section).....................................................249 Direct Pump Test (Charge Section).......................................................251 Direct Pump Test (High Flow Section)....................................................255 High Flow Relief Valve Adjustment.......................................................257 High Flow Relief Valve Removal And Installation.........................................259 Solenoid Removal And Installation.......................................................260 Removal And Installation................................................................261 Hydraulic Pump Start Up.................................................................263 Parts Identification....................................................................264 Disassembly And Assembly................................................................265 HYDRAULIC/HYDROSTATIC FILTERS...............................................................267 Description.............................................................................267 Housing Removal And Installation........................................................267 HYDRAULIC FLUID RESERVOIR...................................................................269 Description.............................................................................269 Removal And Installation................................................................269 Hydraulic Fluid Screen..................................................................272 OIL COOLER..................................................................................273 Description.............................................................................273 Removal And Installation................................................................273 BUCKET POSITION VALVE.......................................................................275 Description.............................................................................275 Solenoid Removal And Installation.......................................................276 Solenoid Testing........................................................................276 Removal And Installation................................................................277 Disassembly And Assembly................................................................277 REAR AUXILIARY DIVERTER VALVE...............................................................279 Description.............................................................................279 Solenoid Testing........................................................................279 Removal And Installation................................................................280 Disassembly And Assembly................................................................282 BOB-TACH (POWER) BLOCK......................................................................289 Description.............................................................................289 Removal And Installation................................................................289 Disassembly And Assembly................................................................291 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.....................................................295 Description.............................................................................295 Removal and Installation................................................................295 Disassembly And Assembly................................................................296 HYDROSTATIC SYSTEM..............................................................................299 HYDROSTATIC SYSTEM INFORMATION..............................................................301 Troubleshooting.........................................................................301 Description.............................................................................302 HYDROSTATIC MOTOR...........................................................................303 Description.............................................................................303 Removing And Replacing Oil..............................................................303 Removal And Installation................................................................304 Parts Identification....................................................................306 Disassembly And Assembly................................................................308 CHARGE PRESSURE.............................................................................321 Description.............................................................................321 Testing.................................................................................321 Sender Removal And Installation.........................................................323 Adjusting...............................................................................324 HYDROSTATIC PUMP............................................................................327 Description.............................................................................327 Removal And Installation................................................................327 Hydrostatic Pump Start Up...............................................................328 Replenishing / High Pressure Relief Valve Removal And Installation......................329 Parts Identification (Left Half)........................................................330 Parts Identification (Right Half).......................................................331 Disassembly.............................................................................332 Assembly................................................................................339 HYDROSTATIC PUMP (SJC)......................................................................345 Description.............................................................................345 Hydraulic Controller Removal And Installation...........................................346 Removal And Installation................................................................348 Hydrostatic Pump Start Up...............................................................350 Parts Identification....................................................................351 High Pressure Relief And Bypass Valve...................................................352 Charge Relief Valve.....................................................................353 Disassembly And Assembly................................................................354 Mechanical Neutral Adjustment...........................................................371 Hydraulic Controller Neutral Adjustment.................................................374 DRIVE BELT..................................................................................377 Description.............................................................................377 Drive Belt Shield Removal And Installation..............................................377 Adjusting...............................................................................378 Belt Removal And Installation...........................................................378 Tensioner Pulley Removal And Installation...............................................379 Tensioner Pulley Disassembly And Assembly...............................................380 Tensioner Pulley Tension Spring Removal And Installation................................381 Tensioner Pulley Tension Disassembly And Assembly.......................................381 CASE DRAIN FILTER...........................................................................383 Description.............................................................................383 Disassembly And Assembly................................................................383 DRIVE SYSTEM....................................................................................385 BRAKE.......................................................................................387 Description.............................................................................387 Block Removal And Installation..........................................................387 Block Disassembly And Assembly..........................................................388 TRACK CARRIAGE COMPONENTS...................................................................389 Description.............................................................................389 Checking Tension........................................................................390 Adjusting Tension.......................................................................391 Track Removal And Installation..........................................................392 Idler (Front) Removal And Installation..................................................394 Idler (Rear) Removal And Installation...................................................397 Roller Removal And Installation.........................................................397 Sprocket Removal And Installation.......................................................398 Carriage Removal And Installation.......................................................399 Track Damage Identification.............................................................400 MAIN FRAME......................................................................................411 SEAT BAR....................................................................................415 Description.............................................................................415 Removal And Installation................................................................415 Disassembly And Assembly................................................................417 Compression Spring Disassembly And Assembly.............................................418 OPERATOR CAB................................................................................419 Gas Cylinder Removal And Installation...................................................419 Gas Cylinder Bracket Disassembly And Assembly...........................................421 Removal And Installation................................................................422 OPERATOR SEAT (SUSPENSION)..................................................................425 Removal And Installation................................................................425 Slide Rail Removal And Installation.....................................................426 Seat Belt Removal And Installation......................................................426 Lower Cushion Removal And Installation..................................................427 Back Cushion Removal And Installation...................................................428 Shock Removal And Installation..........................................................428 3-Point Seat Belt Removal And Installation..............................................429 BOB-TACH (HAND LEVER).......................................................................431 Description.............................................................................431 Removal And Installation................................................................431 Lever And Wedge Disassembly And Assembly................................................433 Pivot Pin Bushing And Seal Removal And Installation.....................................434 BOB-TACH (POWER - OPTION)...................................................................435 Description.............................................................................435 Removal And Installation................................................................435 Lever And Wedge Disassembly And Assembly................................................437 Pivot Pin Bushing And Seal Removal And Installation.....................................439 LIFT ARMS...................................................................................441 Stabilizer Bar Removal And Installation.................................................441 Link Removal And Installation...........................................................442 Removal And Installation................................................................443 REAR GRILL..................................................................................447 Removal And Installation................................................................447 REAR DOOR...................................................................................449 Removal And Installation................................................................449 Striker Removal And Installation........................................................450 Striker Disassembly And Assembly........................................................450 Striker (Adjusting).....................................................................450 Latch Removal And Installation..........................................................451 FUEL TANK...................................................................................453 Removal And Installation................................................................453 Fuel Level Sender Removal And Installation..............................................455 Fuel Fill Screen Removal And Installation...............................................455 CONTROL PEDALS AND LINKAGES.................................................................457 Description.............................................................................457 Pedal Removal And Installation..........................................................458 Linkage Removal And Installation........................................................459 Pedal (Adjusting).......................................................................460 CONTROL PEDALS (ACS)........................................................................461 Description.............................................................................461 Foot Sensor Removal And Installation....................................................461 Foot Pedal Removal And Installation.....................................................462 Foot Pedal Linkage Disassembly And Assembly.............................................462 CONTROL PANEL...............................................................................463 Description.............................................................................463 Removal And Installation................................................................464 Shock Removal And Installation..........................................................466 Shaft Removal And Installation..........................................................467 Linkage Removal And Installation........................................................468 Pintle Arm Disassembly and Assembly.....................................................472 Linkage Neutral (Adjusting).............................................................473 Linkage Travel (Adjusting)..............................................................477 CONTROL PANEL (SJC).........................................................................481 Description.............................................................................481 Removal And Installation................................................................482 CONTROL HANDLE / LEVER......................................................................485 Description.............................................................................485 Lever Removal And Installation..........................................................485 Boot Removal And Installation...........................................................485 CONTROL HANDLE / LEVER (ACS)................................................................487 Description.............................................................................487 Handle Sensor Removal And Installation..................................................487 Handle Removal And Installation.........................................................490 Handle Disassembly And Assembly.........................................................491 Lever Removal And Installation..........................................................492 Boot Removal And Installation...........................................................493 JOYSTICK CONTROL............................................................................495 Description.............................................................................495 Testing.................................................................................496 Removal And Installation................................................................497 Joystick Mount Removal And Installation.................................................498 ACCESS PANEL (INSIDE).......................................................................499 Removal And Installation (Left).........................................................499 Removal And Installation (Right)........................................................499 ACCESS PANEL (INSIDE).......................................................................501 Removal And Installation (Left).........................................................501 Removal And Installation (Right)........................................................502 WINDOW (REAR)...............................................................................505 Removal.................................................................................505 Installation............................................................................505 WINDOW (TOP)................................................................................507 Removal And Installation................................................................507 WINDOW (SIDE)...............................................................................509 Removal And Installation................................................................509 WINDOW (FRONT DOOR).........................................................................511 Removal (Standard Window)...............................................................511 Installation (Standard Window)..........................................................512 Removal And Installation (Special Applications Window)..................................514 CAB DOOR....................................................................................515 Description.............................................................................515 Removal And Installation................................................................515 Aligning................................................................................516 Adjusting...............................................................................517 Checking Operation......................................................................517 ELECTRICAL SYSTEM & ANALYSIS....................................................................519 ELECTRICAL SCHEMATICS.......................................................................523 ELECTRICAL SYSTEM INFORMATION...............................................................530 Glossary Of Electrical Symbols..........................................................530 Cab Harness Connectors..................................................................533 Mainframe Harness Connectors............................................................534 Description.............................................................................535 Troubleshooting.........................................................................537 Fuse And Relay Location / Identification................................................538 Solenoid Testing........................................................................539 BATTERY.....................................................................................540 Servicing...............................................................................540 Using A Booster Battery (Jump Starting).................................................540 Removal And Installation................................................................542 ALTERNATOR..................................................................................544 Belt Adjustment.........................................................................544 Charging System Inspection..............................................................545 Alternator Voltage Testing..............................................................546 Low Voltage Testing.....................................................................546 High Voltage Testing....................................................................547 Removal And Installation................................................................548 Parts Identification....................................................................549 STARTER.....................................................................................550 Testing.................................................................................550 Removal And Installation................................................................551 Parts Identification....................................................................552 INSTRUMENT PANELS...........................................................................554 Left Panel..............................................................................554 Right Panel (Key Switch)................................................................555 Right Panel (Keyless)...................................................................556 Side And Front Panels...................................................................558 Removal And Installation (Left And Right)...............................................559 Bulb Removal And Installation (Left Only)...............................................562 Key Switch Removal And Installation.....................................................563 Alarm Removal And Installation..........................................................564 Front Panel Removal And Installation....................................................564 LIGHTS......................................................................................566 Front Removal And Installation..........................................................566 Rear Removal And Installation...........................................................567 Cab Light Removal And Installation......................................................567 BOBCAT CONTROLLER (MAIN)....................................................................568 Description.............................................................................568 Connector Identification................................................................569 Removal And Installation................................................................571 BOBCAT CONTROLLER (ACS).....................................................................572 Description.............................................................................572 Connector And Wire Identification.......................................................573 Removal And Installation................................................................574 BOBCAT CONTROLLER (SJC) (DRIVE).............................................................576 Description.............................................................................576 Connector Identification................................................................577 Removal And Installation................................................................579 SPEED SENSORS (SJC).........................................................................580 Description.............................................................................580 Testing.................................................................................580 Removal and Installation................................................................582 DIAGNOSTIC SERVICE CODES....................................................................584 Description.............................................................................584 Service Codes List......................................................................585 BOBCAT INTERLOCK CONTROL SYSTEM (BICS)......................................................592 Description.............................................................................592 Inspecting The BICS Controller (Engine STOPPED - Key ON)................................593 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....593 Inspecting The Seat Bar Sensor (Engine RUNNING).........................................593 Inspecting The Traction Lock (Engine RUNNING)...........................................593 Inspecting The Lift Arm Bypass Control..................................................593 Inspecting Deactivation Of Lift And Tilt Functions (ACS and SJC)........................593 Troubleshooting.........................................................................594 Troubleshooting Chart...................................................................595 SEAT BAR SENSOR.............................................................................596 Description.............................................................................596 Troubleshooting.........................................................................597 Testing.................................................................................598 Removal And Installation................................................................599 Bobcat Interlock Control System (BICS) Circuit Test.....................................600 TRACTION LOCK...............................................................................602 Description.............................................................................602 Troubleshooting.........................................................................603 Inspecting..............................................................................604 Parking Brake Solenoid Removal And Installation.........................................605 CONTROL SYSTEM (ACS)........................................................................606 Description.............................................................................606 Troubleshooting Chart...................................................................607 Handle Sensor Connector Disassembly And Assembly........................................608 Switch Handle Removal...................................................................609 Switch Handle Installation..............................................................611 Actuator Connector Disassembly And Assembly.............................................614 Handle Lock Solenoid Removal And Installation...........................................615 Handle Lock Solenoid Disassembly And Assembly...........................................616 Foot Sensor Disassembly And Assembly....................................................616 Foot Lock Solenoid Removal And Installation.............................................617 ELECTRICAL / HYDRAULIC CONTROLS.............................................................618 Identification Chart....................................................................618 ELECTRICAL / HYDRAULIC CONTROLS (SJC).......................................................620 Identification Chart....................................................................620 SERVICE PC (LAPTOP COMPUTER)................................................................624 Connecting Remote Start Tool............................................................624 Connecting Remote Start Tool (Service Tool).............................................624 CALIBRATION.................................................................................626 Description.............................................................................626 Actuator Testing........................................................................626 Lift And Tilt Calibration (ACS).........................................................628 Lift And Tilt Calibration (SJC).........................................................630 Hydrostatic Pump Calibration (SJC)......................................................632 STEERING DRIFT COMPENSATION.................................................................638 Description.............................................................................638 Selecting And Adjusting.................................................................638 Exiting And Saving......................................................................639 FLYWHEEL RPM SENSOR.........................................................................640 Description.............................................................................640 Adjustment..............................................................................640 CONTROL PANEL SETUP.........................................................................642 Right Panel Setup (Keyless).............................................................642 Attachment Control Information (Keyless)................................................643 PASSWORD SETUP (IF EQUIPPED WITH KEYLESS START).............................................644 Password Description....................................................................644 Changing The Owner Password.............................................................644 Changing The User Passwords.............................................................645 Password Lockout Feature................................................................645 MAINTENANCE CLOCK...........................................................................646 Description.............................................................................646 Setup...................................................................................647 Reset...................................................................................651 BACK-UP ALARM SYSTEM........................................................................652 Description.............................................................................652 Inspecting..............................................................................652 Adjusting Switch Position...............................................................653 Troubleshooting (Standard And ACS)......................................................654 Troubleshooting (Joystick)..............................................................655 Alarm Removal And Installation..........................................................656 Switch Removal And Installation.........................................................656 ENGINE SERVICE..................................................................................658 ENGINE INFORMATION..........................................................................662 Description.............................................................................662 Specifications..........................................................................663 Torque Values...........................................................................668 Troubleshooting.........................................................................669 Engine Removal And Installation.........................................................671 Engine Mount Replacement................................................................677 Compression - Checking..................................................................678 ENGINE SPEED CONTROL........................................................................680 Removal And Installation................................................................680 Cable Removal And Installation..........................................................680 ENGINE SPEED CONTROL (SJC)..................................................................682 Removal And Installation................................................................682 Disassembly And Assembly................................................................684 Speed Control Cable Removal And Installation............................................685 MUFFLER.....................................................................................686 Removal And Installation................................................................686 AIR CLEANER.................................................................................688 Housing Removal And Installation........................................................688 ENGINE COOLING SYSTEM.......................................................................690 Radiator Removal And Installation.......................................................690 Radiator Mount Removal And Installation.................................................692 Hydraulic Fan Motor Description.........................................................693 Axial Fan Housing Removal And Installation..............................................693 Axial Fan Removal And Installation......................................................696 Hydraulic Fan Motor Removal And Installation............................................697 Hydraulic Fan Motor Disassembly And Assembly............................................698 Water Pump Removal And Installation.....................................................699 Water Pump Disassembly And Assembly.....................................................700 Thermostat Housing Removal And Installation.............................................700 LUBRICATION SYSTEM..........................................................................702 Oil Pan Removal And Installation........................................................702 Oil Pump Removal And Installation.......................................................703 Oil Pump Inspection.....................................................................703 Oil Filter Cooler Removal And Installation..............................................705 Engine Oil Pressure - Testing...........................................................706 FUEL SYSTEM.................................................................................708 Fuel Shutoff Solenoid - Checking........................................................708 Fuel Shutoff Solenoid - Removal And Installation........................................708 Fuel Injection Pump Assembly Removal....................................................709 Fuel Injection Pump Assembly Installation...............................................713 Governor Housing Disassembly And Assembly...............................................715 Governor Disassembly And Assembly.......................................................717 Fuel Camshaft Removal And Installation..................................................719 Fuel Injection Pump Removal.............................................................721 Injection Pump Timing...................................................................728 Fuel Injector Removal And Installation..................................................731 Fuel Injector Nozzle Pressure - Checking................................................732 Nozzle Spraying Condition...............................................................733 Valve Seat Tightness....................................................................733 CYLINDER HEAD...............................................................................734 Intake Air Heater - Testing.............................................................734 Intake Air Heater Removal And Installation..............................................734 Valve Clearance Adjustment..............................................................735 Cylinder Head Removal And Installation..................................................737 Cylinder Head Top Clearance.............................................................739 Cylinder Head Disassembly And Assembly..................................................740 Cylinder Head - Servicing...............................................................740 Valve Guide - Checking..................................................................741 Reconditioning The Valve And Valve Seat.................................................743 Valve Spring............................................................................745 Valve Tappets...........................................................................746 Rocker Arm And Shaft - Checking.........................................................747 Push Rod Alignment - Checking...........................................................747 CRANKSHAFT AND PISTONS......................................................................748 Piston And Connecting Rod Removal And Installation......................................748 Piston And Connecting Rod - Servicing...................................................750 Cylinder Bore Checking..................................................................754 Connecting Rod Alignment................................................................755 Crankshaft Gear Removal And Installation................................................755 Crankshaft And Bearings Removal.........................................................756 Crankshaft And Bearings Installation....................................................758 Crankshaft And Bearings - Servicing.....................................................760 CAMSHAFT AND TIMING GEArS...................................................................766 Timing Gearcase Cover Removal And Installation..........................................766 Timing Gears Backlash - Checking........................................................767 Idler Gear And Camshaft Removal and Installation........................................767 Camshaft - Servicing....................................................................768 Idler Gear And Shaft - Servicing........................................................770 TURBOCHARGER................................................................................772 Description.............................................................................772 Testing.................................................................................772 Removal And Installation................................................................773 FLYWHEEL AND HOUSING........................................................................774 Flywheel Removal And Installation.......................................................774 Ring Gear Removal And Installation......................................................774 Housing Removal And Installation........................................................775 EXHAUST GAS RECIRCULATION (EGR) SYSTEM......................................................776 Description.............................................................................776 Testing.................................................................................777 Removal And Installation................................................................780 HEATING, VENTILATION, AIR CONDITIONING..........................................................782 AIR CONDITIONING SYSTEM FLOW................................................................785 Description.............................................................................785 Chart...................................................................................786 Components..............................................................................787 Safety Equipment........................................................................790 REGULAR MAINTENANCE.........................................................................792 Filter Elements Removal And Installation................................................792 Compressor Drive Belt Inspection........................................................793 Condenser...............................................................................794 Air Conditioning Service Chart..........................................................795 A/C Evaporator Coil & Heater Coil.......................................................796 TROUBLESHOOTING.............................................................................798 Blower Motor Does Not Operate...........................................................798 Blower Motor Operates Normally, But Air Flow Is Insufficient............................798 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............798 The Compressor Does Not Operate At All, Or Operates Improperly..........................798 Gauge Pressure Related Troubleshooting..................................................799 Troubleshooting Tree....................................................................801 Temperature / Pressure Chart............................................................805 Poor A/C Performance....................................................................807 HVAC Repair And Leaks...................................................................808 Electrical System.......................................................................809 Engine Coolant Bypassing The Heater Valve...............................................816 Heater Valve Not Opening Or Closing.....................................................817 SYSTEM CHARGING AND RECLAMATION.............................................................818 Refrigerant Identification..............................................................818 Reclamation And Charging With Recovery / Charging Unit..................................819 Charging With A Manifold Gauge Set......................................................821 COMPRESSOR..................................................................................824 Belt Adjustment.........................................................................824 Removal And Installation................................................................824 Oil.....................................................................................825 Oil Check...............................................................................826 Clutch Disassembly And Assembly.........................................................827 CONDENSER...................................................................................832 Removal And Installation................................................................832 RECEIVER / DRIER............................................................................834 Receiver / Drier Removal And Installation...............................................834 Pressure Relief Valve Removal And Installation..........................................835 Pressure Switch Removal And Installation................................................835 Schraeder Valve Removal And Installation................................................836 EVAPORATOR / HEATER UNIT....................................................................838 Removal And Installation................................................................838 THERMOSTAT..................................................................................840 Removal And Installation................................................................840 EXPANSION VALVE.............................................................................842 Removal And Installation................................................................842 EVAPORATOR..................................................................................844 Removal And Installation................................................................844 HEATER COIL.................................................................................846 Removal And Installation With A/C.......................................................846 Removal And Installation Without A/C....................................................848 BLOWER FAN..................................................................................850 Removal And Installation................................................................850 Disassembly And Assembly................................................................851 Connector Identification................................................................853 HEATER VALVE................................................................................854 Removal and Installation................................................................854 Disassembly And Assembly................................................................855 SPECIFICATIONS..................................................................................856 (T300) LOADER SPECIFICATIONS................................................................858 Dimensions..............................................................................858 Performance.............................................................................859 Controls................................................................................859 Engine..................................................................................859 Hydraulic System........................................................................860 Electrical..............................................................................861 Drive System............................................................................861 Capacities..............................................................................861 Tracks..................................................................................861 Ground Pressure.........................................................................861 TORQUE SPECIFICATIONS FOR BOLTS.............................................................862 Torque For General SAE Bolts............................................................862 Torque For General Metric Bolts.........................................................863 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................864 O-ring Face Seal Connection.............................................................864 Straight Thread O-ring Fitting..........................................................865 Tubelines And Hoses.....................................................................865 Flare Fitting...........................................................................866 Port Seal Fitting.......................................................................867 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................868 Specifications..........................................................................868 CONVERSIONS.................................................................................870 Decimal And Millimeter Equivalents......................................................870 U.S. To Metric Conversion Chart.........................................................870 SERVICE MANUAL REVISION.........................................................................872 Revision No: T300 - 1.......................................................................872 Revision No: T300 - 2.......................................................................874
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