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Bobcat T300 Compact Track Loader Service Manual 6987045 (7-16) – PDF DOWNLOAD
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Description
Bobcat T300 Compact Track Loader Service Manual 6987045 (7-16) – PDF DOWNLOAD
FILE DETAILS:
Bobcat T300 Compact Track Loader Service Manual 6987045 (7-16) – PDF DOWNLOAD
Language : English
Pages : 1002
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T300 Compact Track Loader Service Manual 6987045 (7-16) – PDF DOWNLOAD
S/N A5GU20001 & Above
S/N A5GV20001 & 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 6987045 (7-16) – PDF DOWNLOAD
MAINTENANCE SAFETY...................................................................................... 3 CONTENTS................................................................................................ 5 FOREWORD................................................................................................ 7 FOREWORD............................................................................................ 9 SAFETY INSTRUCTIONS................................................................................. 11 FIRE PREVENTION..................................................................................... 13 Maintenance..................................................................................... 13 Operation....................................................................................... 13 Electrical...................................................................................... 13 Hydraulic System................................................................................ 13 Fueling......................................................................................... 13 Starting........................................................................................ 13 Spark Arrester 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......................................................................................... 28 Lowering........................................................................................ 29 Cab Door Sensor................................................................................. 30 Special Applications Kit........................................................................ 30 Special Applications Kit Inspection And Maintenance............................................. 30 Forestry Door And Window Kit.................................................................... 31 Forestry Door And Window Kit Inspection And Maintenance......................................... 31 TRANSPORTING LOADER ON A TRAILER.................................................................... 33 Loading And Unloading........................................................................... 33 Fastening....................................................................................... 33 TOWING THE LOADER................................................................................... 35 Procedure....................................................................................... 35 REMOTE START TOOL KIT-MEL1563....................................................................... 37 Remote Start Tool - MEL1563..................................................................... 37 Service Tool Harness Control - MEL1565.......................................................... 38 Service Tool Harness Communicator - MEL1566..................................................... 39 Remote Start Procedure.......................................................................... 40 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666...................................................... 43 Description..................................................................................... 43 Remote Start Tool (Service Tool) - 7022042...................................................... 44 Loader Service Tool Harness - 6689747........................................................... 45 Computer Service Tool Harness - 6689746......................................................... 46 Remote Start Procedure.......................................................................... 47 SERVICE SCHEDULE.................................................................................... 51 Chart........................................................................................... 51 AIR CLEANER SERVICE................................................................................. 53 Replacing Filter Elements....................................................................... 53 ENGINE COOLING SYSTEM............................................................................... 55 Maintenance Platform............................................................................ 55 Description..................................................................................... 55 Cleaning (Earlier Models)....................................................................... 55 Cleaning (Later Models)......................................................................... 56 Removing And Replacing Coolant.................................................................. 58 Checking Level.................................................................................. 58 FUEL SYSTEM......................................................................................... 59 Fuel Specifications............................................................................. 59 Biodiesel Blend Fuel............................................................................ 59 Filling The Fuel Tank........................................................................... 60 Fuel Filter..................................................................................... 60 Removing Air From The Fuel System............................................................... 61 ENGINE LUBRICATION SYSTEM........................................................................... 63 Checking And Adding Engine Oil.................................................................. 63 Engine Oil Chart................................................................................ 63 Removing And Replacing Oil And Filter........................................................... 64 HYDRAULIC / HYDROSTATIC SYSTEM...................................................................... 65 Checking And Adding Fluid....................................................................... 65 Hydraulic / Hydrostatic Fluid Chart............................................................. 65 Removing And Replacing Hydraulic Fluid.......................................................... 66 Removing And Replacing Hydraulic / Hydrostatic Filter........................................... 67 Removing And Replacing Case Drain Filters....................................................... 68 Removing And Replacing Hydraulic Charge Filter.................................................. 69 Breather Cap.................................................................................... 70 BOB-TACH (HAND LEVER)............................................................................... 71 Inspection And Maintenance...................................................................... 71 BOB-TACH (POWER).................................................................................... 73 Inspection And Maintenance...................................................................... 73 LUBRICATING THE LOADER.............................................................................. 75 Lubrication Locations........................................................................... 75 SPARK ARRESTER MUFFLER.............................................................................. 77 Cleaning Procedure.............................................................................. 77 PIVOT PINS.......................................................................................... 79 Inspection And Maintenance...................................................................... 79 LOADER STORAGE AND RETURN TO SERVICE................................................................ 81 Storage......................................................................................... 81 Return To Service............................................................................... 81 STOPPING THE ENGINE AND LEAVING THE LOADER.......................................................... 83 Procedure....................................................................................... 83 EMERGENCY EXIT...................................................................................... 85 Rear Window..................................................................................... 85 Front Door...................................................................................... 85 SEAT BELT........................................................................................... 87 Inspection And Maintenance...................................................................... 87 HYDRAULIC SYSTEM........................................................................................ 89 HYDRAULIC/HYDROSTATIC SCHEMATICS ................................................................... 95 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).....................................................................................119 Testing.........................................................................................119 Removal And Installation........................................................................120 Base End Pivot Pin Removal And Installation.....................................................122 Parts Identification............................................................................123 Disassembly.....................................................................................124 Assembly........................................................................................126 CYLINDER (BOB-TACH).................................................................................129 Testing.........................................................................................129 Removal And Installation........................................................................130 Parts Identification............................................................................131 Disassembly.....................................................................................132 Assembly........................................................................................133 MAIN RELIEF VALVE...................................................................................137 Description.....................................................................................137 Testing.........................................................................................138 Adjusting.......................................................................................140 Removal And Installation........................................................................141 HYDRAULIC CONTROL VALVE (STANDARD)..................................................................143 Description.....................................................................................143 Removal And Installation........................................................................144 Identification Chart............................................................................148 Mount Bracket Removal And Installation..........................................................149 Lift Load Check Valve Removal And Installation..................................................149 Load Check Valve Removal And Installation (Tilt And Auxiliary)..................................150 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..................................150 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...................151 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...................152 Port Relief Valve Removal And Installation......................................................153 Plug Removal And Installation...................................................................154 Rubber Boot Removal And Installation............................................................155 End Cap Block Removal And Installation..........................................................156 Lift Spool And Detent Removal And Installation..................................................157 Tilt Spool Removal And Installation.............................................................167 Auxiliary Spool Removal And Installation........................................................169 Auxiliary Solenoid Removal And Installation (S/N A5GU34999 & Below And A5GV34999 & Below).......171 Solenoid Removal And Installation...............................................................173 Lock Valve Removal And Installation.............................................................174 Lift Arm Bypass Orifice Removal And Installation................................................176 Main Relief Valve Removal And Installation......................................................176 Check Valve Removal And Installation............................................................177 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)..............................................................179 Description.....................................................................................179 Removal And Installation........................................................................180 Actuator Removal And Installation (In Loader)...................................................184 Actuator Removal And Installation (Out Of Loader)...............................................186 Identification Chart............................................................................189 Mount Bracket Removal And Installation..........................................................190 Lift Load Check Valve Removal And Installation..................................................190 Load Check Valve Removal And Installation (Tilt And Auxiliary)..................................191 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..................................192 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...................193 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...................193 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)....................194 Port Relief Valve Removal And Installation......................................................194 Plug Removal And Installation...................................................................195 End Cap Block Removal And Installation..........................................................196 Lift Spool And Detent Removal And Installation..................................................197 Tilt Spool Removal And Installation.............................................................202 Auxiliary Spool Removal And Installation........................................................204 Auxiliary Solenoid Removal And Installation (S/N A5GU34999 & Below And A5GV34999 & Below).......206 Auxiliary Solenoid Removal And Installation (S/N A5GU35001 & Above And A5GV35001& Above)........207 Solenoid Removal And Installation...............................................................208 Lock Valve Removal And Installation.............................................................209 Lift Arm Bypass Orifice Removal And Installation................................................211 Main Relief Valve Removal And Installation......................................................211 Check Valve Removal And Installation............................................................212 LIFT ARM BYPASS CONTROL VALVE.......................................................................213 Description.....................................................................................213 Testing.........................................................................................213 Removal And Installation........................................................................213 Disassembly And Assembly........................................................................214 HYDRAULIC PUMP (STANDARD)...........................................................................215 Description.....................................................................................215 Pump Test At Quick Couplers.....................................................................215 Direct Pump Test (Standard Section).............................................................216 Direct Pump Test (Charge Section)...............................................................218 Removal And Installation........................................................................222 Hydraulic Pump Startup..........................................................................224 Parts Identification............................................................................225 Disassembly And Assembly........................................................................226 HYDRAULIC PUMP (STANDARD) (HIGH FLOW)...............................................................227 Description.....................................................................................227 Pump Test At Quick Couplers.....................................................................227 Direct Pump Test (Standard Section).............................................................228 Direct Pump Test (Charge Section)...............................................................230 Direct Pump Test (High Flow Section)............................................................234 High Flow Relief Valve Adjustment...............................................................236 High Flow Relief Valve Removal And Installation.................................................238 Solenoid Removal And Installation...............................................................239 Removal And Installation........................................................................240 Hydraulic Pump Startup..........................................................................242 Parts Identification............................................................................243 Disassembly And Assembly........................................................................244 HYDRAULIC PUMP (SJC)................................................................................245 Description.....................................................................................245 Pump Test At Quick Couplers.....................................................................245 Direct Pump Test (Standard Section).............................................................246 Direct Pump Test (Charge Section)...............................................................248 Removal And Installation........................................................................252 Hydraulic Pump Startup..........................................................................254 Parts Identification............................................................................255 Disassembly And Assembly........................................................................256 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 Startup..........................................................................273 Parts Identification............................................................................274 Disassembly And Assembly........................................................................275 HYDRAULIC / HYDROSTATIC FILTERS.....................................................................277 Description.....................................................................................277 Housing Removal And Installation................................................................277 HYDRAULIC FLUID RESERVOIR...........................................................................279 Description.....................................................................................279 Removal And Installation........................................................................279 Hydraulic Fluid Screen..........................................................................282 OIL COOLER..........................................................................................283 Description.....................................................................................283 Removal And Installation........................................................................283 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 Description.....................................................................................313 Troubleshooting.................................................................................314 HYDROSTATIC DRIVE 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 Startup........................................................................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) (S/N A5GU20001 - A5GU35031 AND A5GV20001 - A5GV35000)........................357 Description.....................................................................................357 Hydraulic Controller Removal And Installation...................................................358 Removal And Installation........................................................................360 Hydrostatic Pump Startup........................................................................362 Parts Identification............................................................................363 High Pressure Relief And Bypass Valve...........................................................364 Charge Relief Valve.............................................................................365 Disassembly And Assembly........................................................................366 Mechanical Neutral Adjustment...................................................................382 Hydraulic Controller Neutral Adjustment.........................................................385 HYDROSTATIC PUMP (SJC) (S/N A5GU35032 & ABOVE AND A5GV35001 & ABOVE)................................389 Description.....................................................................................389 Hydraulic Controller Removal And Installation...................................................390 Removal And Installation........................................................................392 Hydrostatic Pump Startup........................................................................393 Parts Identification............................................................................394 High Pressure Relief And Bypass Valve...........................................................395 Charge Relief Valve.............................................................................396 Disassembly And Assembly........................................................................397 Mechanical Neutral Adjustment...................................................................410 Hydraulic Controller Neutral Adjustment.........................................................413 DRIVE BELT..........................................................................................417 Description.....................................................................................417 Shield Removal And Installation.................................................................417 Adjusting.......................................................................................418 Belt Removal And Installation...................................................................418 Tensioner Pulley Removal And Installation.......................................................419 Tensioner Pulley Disassembly And Assembly.......................................................420 Tensioner Pulley Tension Spring Removal And Installation........................................421 Tensioner Pulley Tension Spring Disassembly And Assembly........................................421 CASE DRAIN FILTER...................................................................................423 Description.....................................................................................423 Disassembly And Assembly........................................................................423 DRIVE SYSTEM............................................................................................425 BRAKE...............................................................................................427 Description.....................................................................................427 Block Removal And Installation..................................................................427 Block Disassembly And Assembly..................................................................429 TRACK UNDERCARRIAGE (SOLID-MOUNTED) (RUBBER TRACK) (S/N A5GU20394 & BELOW AND A5GV20117 & BELOW)....431 Description.....................................................................................431 Checking Tension................................................................................432 Adjusting Tension...............................................................................433 Track Removal And Installation..................................................................434 Idler (Front) Removal And Installation (S/N A5GU20175 & Below And A5GV20088 & Below)............436 Idler (Front) Removal And Installation (S/N A5GU20176 & Above And A5GV20089 & Above)............438 Track Tensioner Disassembly And Assembly (S/N A5GU20175 & Below And A5GV20088 & Below)..........441 Track Tensioner Disassembly And Assembly (S/N A5GU20176 & Above And A5GV20088 & Above)..........442 Idler (Rear) Removal And Installation...........................................................444 Roller Removal And Installation.................................................................444 Sprocket Removal And Installation...............................................................445 Track Housing Removal And Installation..........................................................446 TRACK UNDERCARRIAGE (SOLID-MOUNTED) (RUBBER TRACK) (S/N A5GU20395 & ABOVE AND A5GV20118 & ABOVE)....447 Description.....................................................................................447 Checking Tension................................................................................448 Adjusting Tension...............................................................................449 Track Removal And Installation..................................................................450 Idler (Front) Removal And Installation..........................................................452 Idler (Rear) Removal And Installation...........................................................457 Roller Removal And Installation.................................................................457 Sprocket Removal And Installation...............................................................458 Track Housing Removal And Installation..........................................................459 TRACK UNDERCARRIAGE (ROLLER SUSPENSION) (RUBBER TRACK)..............................................461 Description.....................................................................................461 Checking Tension................................................................................462 Adjusting Tension...............................................................................463 Track Removal And Installation..................................................................464 Idler (Front) Removal And Installation (S/N A5GU20109 & Below And A5GV20057 & Below)............466 Idler (Front) Removal And Installation (S/N A5GU20110 & Above And A5GV20058 & Above)............468 Track Tensioner Disassembly And Assembly (S/N A5GU20109 & Below And A5GV20057 & Below)..........471 Track Tensioner Disassembly And Assembly (S/N A5GU20110 & Above And A5GV20058 & Above)..........472 Idler (Rear) Removal And Installation...........................................................474 Roller Removal And Installation.................................................................474 Leaf Spring Removal And Installation............................................................475 Sprocket Removal And Installation...............................................................476 Track Housing Removal And Installation..........................................................477 TRACK UNDERCARRIAGE (STEEL TRACK)...................................................................479 Description.....................................................................................479 Checking Tension................................................................................480 Adjusting Tension...............................................................................481 Track Shoe Removal And Installation.............................................................482 Track Removal...................................................................................482 Track Installation..............................................................................484 Idler (Front) Removal And Installation..........................................................486 Track Tensioner Removal.........................................................................486 Track Tensioner Installation....................................................................487 Track Tensioner Disassembly And Assembly........................................................488 Idler (Rear) Removal And Installation...........................................................489 Roller Removal And Installation.................................................................490 Top Roller Removal And Installation.............................................................490 Sprocket Removal And Installation...............................................................491 Track Housing Removal And Installation..........................................................492 TRACK MAINTENANCE (RUBBER TRACK)....................................................................493 Track Damage Identification.....................................................................493 MAINFRAME...............................................................................................505 SEAT BAR............................................................................................509 Description.....................................................................................509 Removal And Installation........................................................................509 Disassembly And Assembly........................................................................510 Compression Spring Disassembly And Assembly.....................................................511 OPERATOR CAB........................................................................................513 Gas Cylinder Removal And Installation...........................................................513 Gas Cylinder Bracket Disassembly And Assembly...................................................515 Removal And Installation........................................................................516 OPERATOR SEAT (SUSPENSION)..........................................................................519 Removal And Installation........................................................................519 Slide Rail Removal And Installation.............................................................520 Seat Belt Removal And Installation..............................................................520 Lower Cushion Removal And Installation..........................................................521 Back Cushion Removal And Installation...........................................................522 Shock Removal And Installation..................................................................522 3-Point Seat Belt Removal And Installation......................................................523 BOB-TACH (HAND LEVER)...............................................................................525 Description.....................................................................................525 Removal And Installation........................................................................525 Lever And Wedge Disassembly And Assembly........................................................527 Pivot Pin Bushing And Seal Removal And Installation.............................................529 BOB-TACH (POWER)....................................................................................531 Description.....................................................................................531 Removal And Installation........................................................................531 Lever And Wedge Disassembly And Assembly........................................................533 Pivot Pin Bushing And Seal Removal And Installation.............................................535 LIFT ARMS...........................................................................................537 Stabilizer Bar Removal And Installation.........................................................537 Link Removal And Installation...................................................................538 Removal And Installation........................................................................539 REAR GRILLE.........................................................................................543 Removal And Installation........................................................................543 REAR DOOR (TAILGATE)................................................................................545 Removal And Installation........................................................................545 Striker Removal And Installation................................................................546 Striker Disassembly And Assembly................................................................546 Striker (Adjusting).............................................................................547 Latch Removal And Installation..................................................................548 FUEL TANK...........................................................................................549 Removal And Installation........................................................................549 Fuel Level Sender Removal And Installation......................................................551 Fuel Fill Screen Removal And Installation.......................................................551 CONTROL PEDALS AND LINKAGES.........................................................................553 Description.....................................................................................553 Pedal Removal And Installation..................................................................554 Linkage Removal And Installation................................................................555 Pedal (Adjusting)...............................................................................556 CONTROL PEDALS (ACS)................................................................................557 Description.....................................................................................557 Foot Sensor Removal And Installation............................................................557 Foot Pedal Removal And Installation.............................................................558 Foot Pedal Linkage Disassembly And Assembly.....................................................558 CONTROL PANEL.......................................................................................559 Description.....................................................................................559 Removal And Installation........................................................................560 Shock Removal And Installation..................................................................562 Shaft Removal And Installation..................................................................563 Linkage Removal And Installation................................................................564 Pintle Arm Disassembly And Assembly.............................................................568 Linkage Neutral (Adjusting).....................................................................569 Linkage Travel (Adjusting)......................................................................573 CONTROL PANEL (SJC).................................................................................577 Description.....................................................................................577 Removal And Installation........................................................................578 CONTROL HANDLE / LEVER..............................................................................581 Description.....................................................................................581 Lever Removal And Installation..................................................................581 Boot Removal And Installation...................................................................581 CONTROL HANDLE / LEVER (ACS)........................................................................583 Description.....................................................................................583 Handle Sensor Removal And Installation..........................................................583 Handle Removal And Installation.................................................................586 Handle Disassembly And Assembly.................................................................587 Lever Removal And Installation..................................................................588 Boot Removal And Installation...................................................................589 CONTROL HANDLE / LEVER (SJC)........................................................................591 Description.....................................................................................591 Joystick Testing................................................................................592 Joystick Removal And Installation...............................................................593 Joystick Mount Removal And Installation.........................................................594 ACCESS PANEL (INSIDE)...............................................................................595 Removal And Installation (Left).................................................................595 Removal And Installation (Right)................................................................595 ACCESS PANEL (INSIDE) (SJC).........................................................................597 Removal And Installation (Left).................................................................597 Removal And Installation (Right)................................................................598 WINDOW (REAR).......................................................................................601 Removal.........................................................................................601 Installation (Split Molding)....................................................................601 Installation (Continuous Molding)...............................................................603 WINDOW (TOP)........................................................................................605 Removal And Installation........................................................................605 WINDOW (SIDE).......................................................................................607 Removal And Installation........................................................................607 WINDOW (CAB DOOR)...................................................................................609 Removal (Standard Window).......................................................................609 Installation (Standard Window)..................................................................610 Removal And Installation (Special Applications Window)..........................................612 CAB DOOR............................................................................................613 Description.....................................................................................613 Removal And Installation........................................................................613 Aligning........................................................................................614 Adjusting.......................................................................................615 Checking Operation..............................................................................615 ELECTRICAL SYSTEM AND ANALYSIS..........................................................................617 ELECTRICAL SCHEMATICS ..............................................................................621 ELECTRICAL SYSTEM INFORMATION.......................................................................627 Glossary Of Electrical Symbols..................................................................627 Cab Harness Connectors..........................................................................630 Mainframe Harness Connectors....................................................................631 Description.....................................................................................632 Troubleshooting.................................................................................633 Fuse And Relay Location / Identification........................................................634 Solenoid Testing................................................................................635 BATTERY.............................................................................................637 Removal And Installation........................................................................637 Servicing.......................................................................................638 Using A Booster Battery (Jump Starting).........................................................639 ALTERNATOR..........................................................................................641 Belt Adjustment.................................................................................641 Belt Replacement................................................................................641 Charging System Inspection......................................................................642 Alternator Voltage Testing......................................................................643 Low Voltage Testing.............................................................................643 High Voltage Testing............................................................................644 Removal And Installation........................................................................645 Parts Identification............................................................................646 STARTER.............................................................................................647 Testing.........................................................................................647 Removal And Installation........................................................................648 Parts Identification............................................................................649 INSTRUMENT PANELS...................................................................................651 Left Panel......................................................................................651 Standard Key Panel..............................................................................653 Keyless Start Panel.............................................................................653 Deluxe Instrumentation Panel....................................................................654 Side Panel......................................................................................655 Front Panel.....................................................................................655 Front Panel Removal And Installation............................................................656 Removal And Installation (Left And Right).......................................................656 Key Switch Removal And Installation.............................................................658 Alarm Removal And Installation..................................................................659 LIGHTS..............................................................................................661 Front Removal And Installation..................................................................661 Rear Removal And Installation...................................................................662 Cab Light Removal And Installation..............................................................662 BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)..........................................................663 Description.....................................................................................663 Connector Identification........................................................................664 Removal And Installation........................................................................670 BOBCAT CONTROLLER (ACS).............................................................................671 Description.....................................................................................671 Connector And Wire Identification...............................................................672 Removal And Installation........................................................................673 BOBCAT CONTROLLER (SJC) (DRIVE).....................................................................675 Description.....................................................................................675 Connector Identification........................................................................676 Removal And Installation........................................................................678 SPEED SENSORS (SJC).................................................................................679 Description.....................................................................................679 Testing.........................................................................................679 Removal And Installation........................................................................680 DIAGNOSTIC SERVICE CODES............................................................................683 Viewing Service Codes...........................................................................683 Service Codes List..............................................................................684 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™).............................................................689 Description.....................................................................................689 Inspecting The BICS™ (Engine STOPPED - Key ON)..................................................690 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)............690 Inspecting The Seat Bar Sensor (Engine RUNNING).................................................690 Inspecting The Traction Lock (Engine RUNNING)...................................................690 Inspecting The Lift Arm Bypass Control..........................................................690 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)................................690 Troubleshooting.................................................................................691 SEAT BAR SENSOR.....................................................................................693 Description.....................................................................................693 Troubleshooting.................................................................................693 Testing.........................................................................................694 Removal And Installation........................................................................695 Bobcat Interlock Control System (BICS™) Circuit Test............................................698 TRACTION LOCK.......................................................................................701 Description.....................................................................................701 Troubleshooting.................................................................................702 Inspecting......................................................................................703 CONTROL SYSTEM (ACS)................................................................................705 Description.....................................................................................705 Troubleshooting.................................................................................706 Handle Sensor Connector Disassembly And Assembly................................................707 Switch Handle Removal...........................................................................708 Switch Handle Installation......................................................................710 Actuator Connector Disassembly And Assembly.....................................................713 Handle Lock Solenoid Removal And Installation...................................................714 Handle Lock Solenoid Disassembly And Assembly...................................................715 Foot Sensor Removal And Installation............................................................715 Foot Sensor Disassembly And Assembly............................................................716 Foot Sensor Lock Solenoid Removal And Installation..............................................717 ELECTRICAL / HYDRAULIC CONTROLS.....................................................................719 Identification Chart............................................................................719 Description.....................................................................................720 Identification Chart ACD Group 0................................................................721 Identification Chart ACD Group 1................................................................722 Identification Chart ACD Group 2................................................................723 Identification Chart ACD Group 3................................................................724 ELECTRICAL / HYDRAULIC CONTROLS (ACS)...............................................................725 Identification Chart............................................................................725 Description.....................................................................................726 Identification Chart ACD Group 0................................................................727 Identification Chart ACD Group 1................................................................728 Identification Chart ACD Group 2................................................................729 Identification Chart ACD Group 3................................................................730 ELECTRICAL / HYDRAULIC CONTROLS (SJC)...............................................................731 Identification Chart............................................................................731 Description.....................................................................................732 Identification Chart ACD Group 0................................................................733 Identification Chart ACD Group 1................................................................734 Identification Chart ACD Group 2................................................................735 Identification Chart ACD Group 3................................................................736 SERVICE PC (LAPTOP COMPUTER)........................................................................737 Connecting Remote Start Tool....................................................................737 Connecting Remote Start Tool (Service Tool).....................................................737 CALIBRATION.........................................................................................739 Description.....................................................................................739 Actuator Testing................................................................................739 Lift And Tilt Calibration (SJC).................................................................742 Hydrostatic Pump Calibration (SJC)..............................................................744 Lift And Tilt Calibration (ACS).................................................................749 STEERING DRIFT COMPENSATION.........................................................................751 Description.....................................................................................751 Operation.......................................................................................751 FLYWHEEL RPM SENSOR.................................................................................753 Description.....................................................................................753 Adjustment......................................................................................754 CONTROL PANEL SETUP.................................................................................755 Right Panel Setup (Deluxe Instrumentation Panel)................................................755 Attachment Control Information (Deluxe Instrumentation Panel)...................................756 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL).......................................................757 Password Description............................................................................757 Changing The Owner Password.....................................................................757 Changing The User Passwords.....................................................................758 Password Lockout Feature........................................................................758 PASSWORD SETUP (KEYLESS START PANEL)................................................................759 Password Description............................................................................759 Changing The Owner Password.....................................................................759 Password Lockout Feature........................................................................759 MAINTENANCE CLOCK...................................................................................761 Description.....................................................................................761 Setup...........................................................................................762 Reset...........................................................................................765 BACK-UP ALARM SYSTEM................................................................................767 Description.....................................................................................767 Inspecting......................................................................................767 Adjusting Switch Position.......................................................................768 Troubleshooting (Standard And ACS)..............................................................769 Troubleshooting (Joystick)......................................................................770 Alarm Removal And Installation..................................................................771 Switch Removal And Installation.................................................................771 ENGINE SERVICE..........................................................................................773 ENGINE INFORMATION..................................................................................777 Description.....................................................................................777 Specifications..................................................................................778 Torque Values...................................................................................783 Troubleshooting.................................................................................784 Engine Removal And Installation.................................................................786 Engine Mount Replacement........................................................................792 Compression - Checking..........................................................................793 ENGINE SPEED CONTROL................................................................................795 Removal And Installation........................................................................795 Cable Removal And Installation..................................................................795 ENGINE SPEED CONTROL (SJC)..........................................................................797 Removal And Installation........................................................................797 Disassembly And Assembly........................................................................799 Cable Removal And Installation..................................................................800 MUFFLER.............................................................................................801 Removal And Installation........................................................................801 AIR CLEANER.........................................................................................803 Housing Removal And Installation................................................................803 ENGINE COOLING SYSTEM...............................................................................805 Radiator Removal And Installation...............................................................805 Radiator Mount Removal And Installation.........................................................807 Hydraulic Fan Motor Description.................................................................808 Axial Fan Housing Removal And Installation......................................................809 Axial Fan Removal And Installation..............................................................811 Hydraulic Fan Motor Removal And Installation....................................................813 Hydraulic Fan Motor Disassembly And Assembly....................................................813 Water Pump Removal And Installation.............................................................815 Water Pump Disassembly And Assembly.............................................................815 Thermostat Housing Removal And Installation.....................................................816 Thermostat - Checking...........................................................................816 LUBRICATION SYSTEM..................................................................................817 Oil Pan Removal And Installation................................................................817 Oil Pump Removal And Installation...............................................................818 Oil Pump Inspection.............................................................................818 Oil Filter Cooler Removal And Installation......................................................820 Engine Oil Pressure - Testing...................................................................821 FUEL SYSTEM.........................................................................................823 Fuel Shutoff Solenoid - Checking................................................................823 Fuel Shutoff Solenoid Removal And Installation..................................................823 Fuel Injection Pump Assembly Removal............................................................824 Fuel Injection Pump Assembly Installation.......................................................828 Governor Housing Disassembly And Assembly.......................................................830 Governor Disassembly And Assembly...............................................................832 Fuel Camshaft Removal And Installation..........................................................834 Fuel Injection Pump Removal.....................................................................836 Fuel Injection Pump Installation................................................................839 Fuel Injection Pump - Timing....................................................................843 Fuel Injector Removal And Installation..........................................................846 Fuel Injector Nozzle Pressure - Checking........................................................847 Nozzle Spraying Condition.......................................................................848 Valve Seat Tightness............................................................................848 CYLINDER HEAD.......................................................................................849 Intake Air Heater - Testing.....................................................................849 Intake Air Heater Removal And Installation......................................................849 Valve Clearance Adjustment......................................................................850 Cylinder Head Removal And Installation..........................................................852 Cylinder Head Disassembly And Assembly..........................................................854 Cylinder Head - Servicing.......................................................................854 Cylinder Head Top Clearance.....................................................................855 Valve Guide - Checking..........................................................................856 Reconditioning The Valve And Valve Seat.........................................................858 Valve Spring....................................................................................860 Valve Tappets...................................................................................861 Rocker Arm And Shaft - Checking.................................................................862 Push Rod Alignment - Checking...................................................................862 CRANKSHAFT AND PISTONS..............................................................................863 Piston And Connecting Rod Removal And Installation..............................................863 Piston And Connecting Rod - Servicing...........................................................865 Cylinder Bore - Checking........................................................................869 Connecting Rod Alignment........................................................................870 Crankshaft Gear Removal And Installation........................................................870 Crankshaft And Bearings Removal.................................................................871 Crankshaft And Bearings Installation............................................................873 Crankshaft And Bearings - Servicing.............................................................875 CAMSHAFT AND TIMING GEARS...........................................................................881 Timing Gearcase Cover Removal And Installation..................................................881 Timing Gears Backlash - Checking................................................................882 Idler Gear And Camshaft Removal And Installation................................................882 Camshaft - Servicing............................................................................883 Idler Gear And Shaft - Servicing................................................................885 TURBOCHARGER........................................................................................887 Description.....................................................................................887 Testing.........................................................................................887 Removal And Installation........................................................................888 FLYWHEEL AND HOUSING................................................................................889 Flywheel Removal And Installation...............................................................889 Ring Gear Removal And Installation..............................................................889 Housing Removal And Installation................................................................890 EXHAUST GAS RECIRCULATION (EGR) SYSTEM..............................................................891 Description.....................................................................................891 Testing.........................................................................................892 Removal And Installation........................................................................895 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................897 AIR CONDITIONING SYSTEM FLOW........................................................................899 Description.....................................................................................899 Chart...........................................................................................900 Components......................................................................................901 Safety Equipment................................................................................904 REGULAR MAINTENANCE.................................................................................905 Filters.........................................................................................905 Compressor Drive Belt Adjustment................................................................906 Compressor Drive Belt Replacement...............................................................906 Condenser.......................................................................................907 Air Conditioning Lubrication....................................................................907 Air Conditioning Service Chart..................................................................908 Evaporator / Heater Coil........................................................................909 TROUBLESHOOTING.....................................................................................911 Blower Motor Does Not Operate...................................................................911 Blower Motor Operates Normally, But Air Flow Is Insufficient....................................911 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal......................911 The Compressor Does Not Operate At All, Or Operates Improperly..................................911 Gauge Pressure Related Troubleshooting..........................................................912 Troubleshooting Tree............................................................................914 Temperature / Pressure Chart....................................................................918 Poor A/C Performance............................................................................920 HVAC Repair And Leaks...........................................................................921 Electrical System...............................................................................922 Engine Coolant Bypassing The Heater Valve.......................................................929 Heater Valve Not Opening Or Closing.............................................................930 SYSTEM CHARGING AND RECLAMATION.....................................................................931 Refrigerant Identification......................................................................931 Reclamation And Charging With Recovery / Charging Unit..........................................932 Charging With A Manifold Gauge Set..............................................................934 COMPRESSOR..........................................................................................937 Removal And Installation........................................................................937 Oil.............................................................................................938 Oil Check.......................................................................................939 Clutch Disassembly And Assembly.................................................................940 CONDENSER...........................................................................................945 Removal And Installation........................................................................945 RECEIVER / DRIER....................................................................................947 Receiver / Drier Removal And Installation.......................................................947 Pressure Relief Valve Removal And Installation..................................................948 Pressure Switch Removal And Installation........................................................948 Schraeder Valve Removal And Installation........................................................949 EVAPORATOR / HEATER UNIT............................................................................951 Removal And Installation........................................................................951 THERMOSTAT..........................................................................................953 Description.....................................................................................953 Removal And Installation........................................................................954 EXPANSION VALVE.....................................................................................955 Removal And Installation........................................................................955 EVAPORATOR COIL.....................................................................................957 Removal And Installation........................................................................957 HEATER COIL.........................................................................................959 Removal And Installation With A/C...............................................................959 Removal And Installation Without A/C............................................................961 BLOWER FAN..........................................................................................963 Removal And Installation........................................................................963 Disassembly And Assembly........................................................................964 Connector Identification........................................................................966 HEATER VALVE........................................................................................967 Removal And Installation........................................................................967 Disassembly And Assembly........................................................................968 SPECIFICATIONS..........................................................................................969 (T300) LOADER SPECIFICATIONS........................................................................971 Machine Dimensions..............................................................................971 Performance.....................................................................................972 Hydraulic System................................................................................972 Engine..........................................................................................973 Controls........................................................................................973 Drive System....................................................................................973 Electrical......................................................................................974 Capacities......................................................................................974 Tracks..........................................................................................974 Ground Pressure.................................................................................974 TORQUE SPECIFICATIONS FOR BOLTS.....................................................................975 Torque For General SAE Bolts....................................................................975 Torque For General Metric Bolts.................................................................976 HYDRAULIC CONNECTION SPECIFICATIONS.................................................................977 O-Ring Face Seal Connection.....................................................................977 Straight Thread O-Ring Fitting..................................................................978 Tubelines And Hoses.............................................................................978 Flare Fitting...................................................................................979 Port Seal Fitting...............................................................................980 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS........................................................981 Specifications..................................................................................981 CONVERSIONS.........................................................................................983 Decimal And Millimeter Equivalent Chart.........................................................983 U.S. To Metric Conversion Chart.................................................................983 SERVICE TOOLS REQUIRED..............................................................................985 Remote Start Tools..............................................................................985 Hydraulic Tools.................................................................................986 Electrical Tools................................................................................990 Engine Tools....................................................................................991 HVAC Tools......................................................................................996 ALPHABETICAL INDEX......................................................................................997
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