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Bobcat T300 Turbo T300 Turbo High Flow Loader Service Manual 6902726 (6-12) – PDF DOWNLOAD
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Bobcat T300 Turbo T300 Turbo High Flow Loader Service Manual 6902726 (6-12) – PDF DOWNLOAD
S/N 525411001 & Above
S/N 525511001 & Above
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Description
Bobcat T300 Turbo T300 Turbo High Flow Loader Service Manual 6902726 (6-12) – PDF DOWNLOAD
FILE DETAILS:
Bobcat T300 Turbo T300 Turbo High Flow Loader Service Manual 6902726 (6-12) – PDF DOWNLOAD
Language : English
Pages : 1076
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T300 Turbo T300 Turbo High Flow Loader Service Manual 6902726 (6-12) – PDF DOWNLOAD
S/N 525411001 & Above
S/N 525511001 & 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 must be legible and in the correct location.
7. Steering levers and foot pedals must return to neutral.
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 (Optional on some models).
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 Turbo T300 Turbo High Flow Loader Service Manual 6902726 (6-12) – PDF DOWNLOAD
MAINTENANCE SAFETY.................................................................................................... 3 ALPHABETICAL INDEX.................................................................................................... 5 CONTENTS.............................................................................................................. 7 FOREWORD.......................................................................................................... 8 SAFETY INSTRUCTIONS............................................................................................... 11 Fire Prevention............................................................................................... 13 SERIAL NUMBER LOCATION............................................................................................ 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 The Lift Arm Support Device........................................................................ 23 Removing The Lift Arm Support Device.......................................................................... 24 OPERATOR CAB...................................................................................................... 25 Description................................................................................................... 25 Raising The Operator Cab...................................................................................... 25 Lowering The Operator Cab..................................................................................... 26 Emergency Exit................................................................................................ 26 TRANSPORTING THE BOBCAT LOADER.................................................................................... 29 Procedure..................................................................................................... 29 TOWING THE LOADER................................................................................................. 31 Procedure..................................................................................................... 31 REMOTE START...................................................................................................... 33 Procedure For Loader W/O Attachments Control Harness.......................................................... 33 Procedure For Loader With Attachments Control Harness......................................................... 34 Procedure..................................................................................................... 35 SERVICE SCHEDULE.................................................................................................. 37 Chart......................................................................................................... 37 AIR CLEANER SERVICE............................................................................................... 39 Replacing Filter Element...................................................................................... 39 ENGINE COOLING SYSTEM............................................................................................. 41 Cleaning Cooling System....................................................................................... 41 Checking The Coolant Level.................................................................................... 43 Adding The Coolant............................................................................................ 44 FUEL SYSTEM....................................................................................................... 45 Fuel Specifications........................................................................................... 45 Filling The Fuel Tank......................................................................................... 45 Fuel Filter................................................................................................... 46 Removing Air From The Fuel System............................................................................. 46 ENGINE LUBRICATION SYSTEM......................................................................................... 47 Checking Engine Oil........................................................................................... 47 Oil Chart..................................................................................................... 47 Replacing Oil And Filter...................................................................................... 47 HYDRAULIC/HYDROSTATIC SYSTEM...................................................................................... 49 Checking And Adding Fluid..................................................................................... 49 Hydraulic Fluid Chart......................................................................................... 49 Hydraulic/Hydrostatic Filter Replacement...................................................................... 50 Replacing Hydraulic Fluid And Case Drain Filters.............................................................. 51 FAN GEARBOX....................................................................................................... 53 Checking And Adding Oil....................................................................................... 53 POWER BOB-TACH.................................................................................................... 55 Inspection And Maintenance.................................................................................... 55 BOB-TACH.......................................................................................................... 57 Inspection And Maintenance.................................................................................... 57 POWER BOB-TACH.................................................................................................... 59 Inspection And Maintenance.................................................................................... 59 LUBRICATING THE LOADER............................................................................................ 61 Procedure..................................................................................................... 61 HYDRAULIC SYSTEM...................................................................................................... 65 HYDRAULIC/HYDROSTATIC SCHEMATICS.................................................................................. 73 HYDRAULIC SYSTEM INFORMATION...................................................................................... 89 Troubleshooting............................................................................................... 93 Tightening Procedure.......................................................................................... 94 CYLINDER (LIFT)................................................................................................... 95 Checking...................................................................................................... 95 Removal And Installation...................................................................................... 95 Parts Identification.......................................................................................... 97 Disassembly................................................................................................... 98 Assembly...................................................................................................... 99 CYLINDER (TILT)................................................................................................... 103 Checking...................................................................................................... 103 Removal And Installation...................................................................................... 103 Base Pin Removal And Installation............................................................................. 105 Parts Identification.......................................................................................... 106 Disassembly................................................................................................... 107 Assembly...................................................................................................... 108 CYLINDER (POWER BOB-TACH)......................................................................................... 111 Checking...................................................................................................... 111 Removal And Installation...................................................................................... 112 Parts Identification.......................................................................................... 113 Disassembly................................................................................................... 114 Assembly...................................................................................................... 115 MAIN RELIEF VALVE................................................................................................. 119 Checking Main Relief.......................................................................................... 119 Adjustment.................................................................................................... 121 Removal and Installation...................................................................................... 122 HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL).......................................................... 123 Identification................................................................................................ 123 Removal And Installation...................................................................................... 123 BICS™ Valve, Removal And Installation......................................................................... 127 BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation................................................ 129 BICS™ Valve, Check Valve Removal And Installation............................................................. 130 Backslide, Lock Valve Removal And Installation................................................................ 131 BICS™ Valve, Solenoid Removal And Installation................................................................ 132 BICS™ Valve, Solenoid Testing................................................................................. 133 Identification Chart.......................................................................................... 134 Load Check Valve.............................................................................................. 135 Main Relief Valve............................................................................................. 136 Port Relief Valve, Tilt Spool................................................................................. 136 Port Relief Valve, Lift Spool................................................................................. 137 Anti-Cavitation Valve/Port Relief Valve, Tilt Spool........................................................... 137 Anti-Cavitation Valve, Lift Spool............................................................................. 138 Rubber Boot................................................................................................... 138 Lift And Tilt Lock Block...................................................................................... 139 Lift Spool And Detent Removal................................................................................. 140 Lift Spool And Detent Disassembly............................................................................. 142 Lift Spool And Detent Assembly................................................................................ 145 Lift Spool And Detent Installation............................................................................ 149 Tilt Spool Removal And Installation........................................................................... 150 Tilt Spool Disassembly And Assembly........................................................................... 151 Auxiliary Spool Removal And Installation...................................................................... 152 Auxiliary Plug Removal And Installation....................................................................... 154 Auxiliary Electric Solenoid Disassembly....................................................................... 155 Port-Auxiliary Section Removal And Installation............................................................... 156 Cleaning And Inspection....................................................................................... 156 HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)......................................... 157 Identification................................................................................................ 157 Actuator Removal And Installation (In Loader)................................................................. 158 Actuator Removal And Installation (Out Of Loader)............................................................. 160 Actuator Removal And Installation (Out Of Loader) (Cont’d).................................................... 161 Removal And Installation...................................................................................... 162 BICS™ Valve, Removal And Installation......................................................................... 166 BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly................................................ 169 BICS™ Valve, Check Valve Disassembly And Assembly............................................................. 170 BICS™ Valve, Lock Valve Disassembly And Assembly.............................................................. 171 BICS™ Valve, Solenoid Disassembly And Assembly................................................................ 172 BICS™ Valve, Solenoid Testing................................................................................. 173 Identification Chart.......................................................................................... 174 Lift Base End Restrictor...................................................................................... 175 Load Check Valve.............................................................................................. 176 Main Relief Valve............................................................................................. 177 Port Relief Valve............................................................................................. 179 Anti-Cavitation Valve/Port Relief Valve....................................................................... 180 Anti-Cavitation Valve......................................................................................... 181 Lift Spool Removal............................................................................................ 182 Lift Spool Removal And Installation........................................................................... 183 Lift and Tilt Spool Disassembly And Assembly.................................................................. 184 Auxiliary Spool Removal And Installation...................................................................... 185 Auxiliary Electric Solenoid Disassembly....................................................................... 186 Port-Auxiliary Section Disassembly............................................................................ 187 Cleaning And Inspection....................................................................................... 187 HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (selectable joystick control) (sjc)..................................... 189 Identification................................................................................................ 189 Actuator Removal And Installation (In Loader)................................................................. 190 Actuator Removal And Installation (Out Of Loader)............................................................. 192 Removal And Installation...................................................................................... 194 BICS™ Valve, Removal And Installation......................................................................... 198 BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly................................................ 201 BICS™ Valve, Check Valve Disassembly And Assembly............................................................. 202 BICS™ Valve, Lock Valve Disassembly And Assembly.............................................................. 203 BICS™ Valve, Solenoid Disassembly And Assembly................................................................ 204 BICS™ Valve, Solenoid Testing................................................................................. 205 Identification Chart.......................................................................................... 206 Lift Base End Restrictor...................................................................................... 207 Load Check Valve.............................................................................................. 208 Main Relief Valve............................................................................................. 209 Port Relief Valve............................................................................................. 211 Anti-Cavitation Valve/Port Relief Valve....................................................................... 212 Anti-Cavitation Valve......................................................................................... 213 Lift Spool Removal............................................................................................ 214 Lift Spool Removal And Installation........................................................................... 215 Lift And Tilt Spool Disassembly And Assembly.................................................................. 216 Auxiliary Spool Removal And Installation...................................................................... 217 Auxiliary Electric Solenoid Disassembly....................................................................... 218 Port-Auxiliary Section Disassembly............................................................................ 219 Cleaning And Inspection....................................................................................... 219 HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL).......................................................... 221 Removal And Installation...................................................................................... 221 Identification Chart.......................................................................................... 225 BICS™ Valve, Lift Load Check Valve Removal And Installation................................................... 226 Load Check Valve Removal And Installation (Tilt & Auxiliary).................................................. 227 Anti-Cavitation Valve (Lift, Rod End)......................................................................... 227 Anti-Cavitation Valve (Lift, Rod End) (Cont’d)................................................................ 228 Port Relief/Anti-Cavitation Valve (Lift, Base End)............................................................ 228 Port Relief/Anti-Cavitation Valve (Tilt, Base End)............................................................ 229 Port Relief/Anti-Cavitation Valve (Tilt, Rod End)............................................................. 229 Port Relief Valve............................................................................................. 230 Plug Removal.................................................................................................. 231 Rubber Boot Removal and Installation.......................................................................... 232 End Cap/Spool Lock Block Removal and Installation............................................................. 233 Lift Spool and Detent Removal and Installation................................................................ 234 Auxiliary Spool Removal And Installation...................................................................... 246 Auxiliary Solenoid Disassembly and Assembly................................................................... 248 BICS™ Valve Solenoid Disassembly And Assembly................................................................. 249 BICS™ Valve, Lock Valve Removal And Installation.............................................................. 250 BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly................................................ 252 Main Relief Valve............................................................................................. 253 BICS™ Valve, Check Valve Removal and Installation............................................................. 254 HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)......................................... 255 Removal And Installation...................................................................................... 256 Actuator Removal And Installation (In Loader)................................................................. 260 Actuator Removal And Installation (Out of Loader)............................................................. 262 Identification Chart.......................................................................................... 265 BICS™ Valve, Lift Load Check Valve Removal And Installation................................................... 266 Load Check Valve Removal And Installation (Tilt & Auxiliary).................................................. 267 Anti-Cavitation Valve (Lift, Rod End)......................................................................... 267 Port Relief/Anti-Cavitation Valve (Lift, Base End)............................................................ 268 Port Relief/Anti-Cavitation Valve (Tilt, Base End)............................................................ 269 Port Relief/Anti-Cavitation Valve (Tilt, Rod End)............................................................. 269 Port Relief Valve............................................................................................. 270 Plug Removal.................................................................................................. 271 End Cap Block Removal And Installation........................................................................ 272 Lift Spool Removal And Installation........................................................................... 273 Tilt Spool Removal And Installation........................................................................... 277 Auxiliary Spool Removal And Installation...................................................................... 279 Auxiliary Solenoid Disassembly And Assembly................................................................... 281 BICS™ Valve Solenoid Disassembly And Assembly................................................................. 282 BICS™ Valve, Lock Valve Removal And Installation.............................................................. 283 BICS™ Valve, Lock Valve Removal And Installation (Cont’d)..................................................... 284 BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly................................................ 285 Main Relief Valve............................................................................................. 285 BICS™ Valve, Check Valve Removal And Installation............................................................. 286 HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (SELECTABLE JOYSTICK CONTROL) (SJC)..................................... 287 Removal And Installation...................................................................................... 288 Actuator Removal And Installation (In Loader)................................................................. 292 Identification Chart.......................................................................................... 297 BICS™ Valve, Lift Load Check Valve Removal And Installation................................................... 298 Load Check Valve Removal And Installation (Tilt & Auxiliary).................................................. 299 Anti-Cavitation Valve (Lift, Rod End)......................................................................... 299 Port Relief/Anti-Cavitation Valve (Lift, Base End)............................................................ 300 Port Relief/Anti-Cavitation Valve (Tilt, Base End)............................................................ 301 Port Relief/Anti-Cavitation Valve (Tilt, Rod End)............................................................. 301 Port Relief Valve............................................................................................. 302 Plug Removal.................................................................................................. 303 End Cap Block Removal and Installation........................................................................ 304 Lift Spool Removal and Installation........................................................................... 305 Auxiliary Spool Removal And Installation...................................................................... 311 Auxiliary Solenoid Disassembly And Assembly................................................................... 313 BICS™ Valve Solenoid Disassembly And Assembly................................................................. 314 BICS™ Valve, Lock Valve Removal And Installation.............................................................. 315 BICS™ Valve, Lock Valve Removal And Installation (Cont’d)..................................................... 316 BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly................................................ 317 Main Relief Valve............................................................................................. 317 BICS™ Valve, Check Valve Removal And Installation............................................................. 318 LIFT ARM BY-PASS CONTROL VALVE.................................................................................... 319 Inspecting.................................................................................................... 319 Additional Inspection For Loaders W/Advanced Hand Controls.................................................... 319 Removal And Installation...................................................................................... 319 Disassembly And Assembly...................................................................................... 320 HYDRAULIC PUMP.................................................................................................... 321 Check The Output Of The Hydraulic Pump........................................................................ 321 Removal And Installation...................................................................................... 322 Parts Identification.......................................................................................... 324 Disassembly And Assembly...................................................................................... 325 HYDRAULIC PUMP (CHARGE)........................................................................................... 333 Check The Output Of The Hydraulic Pump........................................................................ 333 Removal and Installation...................................................................................... 336 HYDRAULIC PUMP (HIGH FLOW)........................................................................................ 337 Hydraulic Pump Test (30 GPM).................................................................................. 337 Hydraulic Pump Test (40 GPM).................................................................................. 338 Inline Hydraulic Pump Test (Standard)......................................................................... 339 Inline Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM).................................................... 341 High Flow Relief Adjustment Procedure (30 GPM And 40 GPM)..................................................... 343 High Flow Relief Valve Removal And Installation (30 GPM And 40 GPM)........................................... 345 Removal And Installation (30 GPM And 40 GPM).................................................................. 346 Identification (30 GPM) (S/N 525414499 & Below)............................................................... 348 Identification (40 GPM) (S/N 525414500 & Above)............................................................... 349 Disassembly And Assembly (30 GPM And 40 GPM).................................................................. 350 HYDRAULIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC)................................................................ 363 Check The Output Of The Hydraulic Pump........................................................................ 363 Removal And Installation...................................................................................... 364 Identification................................................................................................ 366 Disassembly And Assembly...................................................................................... 367 HYDRAULIC PUMP (HIGH FLOW) (SELECTABLE JOYSTICK CONTROL) (SJC).................................................... 373 Hydraulic Pump Test (30 GPM).................................................................................. 373 Hydraulic Pump Test (40 GPM).................................................................................. 374 Inline Hydraulic Pump Test (Standard)......................................................................... 375 Inline Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM).................................................... 377 High Flow Relief Adjustment Procedure (30 GPM And 40 GPM)..................................................... 379 High Flow Relief Valve Removal And Installation (30 GPM And 40 GPM)........................................... 381 Removal And Installation (30 GPM And 40 GPM).................................................................. 382 Identification (30 GPM) (S/N 525414499 & Below)............................................................... 384 Identification (40 GPM) (S/N 525414500 & Above)............................................................... 385 Disassembly And Assembly (30 GPM And 40 GPM).................................................................. 386 HYDRAULIC/HYDROSTATIC FILTER...................................................................................... 395 Housing Removal And Installation.............................................................................. 395 Mount Removal And Installation................................................................................ 396 HYDRAULIC FLUID RESERVOIR......................................................................................... 397 Fluid Removal................................................................................................. 397 Removal And Installation...................................................................................... 397 Hydraulic Fluid Screen........................................................................................ 400 BUCKET POSITION VALVE............................................................................................. 401 Solenoid Removal And Installation............................................................................. 401 Solenoid Testing.............................................................................................. 401 Removal And Installation...................................................................................... 402 Disassembly And Assembly...................................................................................... 402 REAR AUXILIARY DIVERTER........................................................................................... 405 Removal And Installation...................................................................................... 405 Disassembly And Assembly...................................................................................... 407 Solenoid Testing.............................................................................................. 412 Inspection.................................................................................................... 412 POWER BOB-TACH BLOCK.............................................................................................. 413 Removal And Installation...................................................................................... 413 Disassembly And Assembly...................................................................................... 414 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK........................................................................... 419 Removal and Installation...................................................................................... 419 Disassembly And Assembly...................................................................................... 419 HYDROSTATIC SYSTEM.................................................................................................... 421 HYDROSTATIC SYSTEM INFORMATION.................................................................................... 423 Troubleshooting Chart......................................................................................... 423 Replenishing Valve Function................................................................................... 424 HYDROSTATIC MOTOR................................................................................................. 425 Removal And Installation...................................................................................... 425 Parts Identification.......................................................................................... 428 Disassembly................................................................................................... 430 Inspection.................................................................................................... 438 Assembly...................................................................................................... 439 Filling....................................................................................................... 447 HYDROSTATIC MOTOR (SELECTABLE JOYSTICK CONTROL) (SJC)............................................................. 449 Removal And Installation...................................................................................... 449 Parts Identification.......................................................................................... 452 Disassembly................................................................................................... 454 Inspection.................................................................................................... 463 Assembly...................................................................................................... 464 Filling....................................................................................................... 473 CHARGE PRESSURE................................................................................................... 475 Testing....................................................................................................... 475 Removal and Installation...................................................................................... 477 Setting Charge Pressure....................................................................................... 478 HYDROSTATIC PUMP.................................................................................................. 479 Removal And Installation...................................................................................... 479 Replenishing/High Pressure Relief Valve....................................................................... 481 Parts Identification (Right Half)............................................................................. 482 Parts Identification (Left Half).............................................................................. 484 Hydraulic Pump Removal And Installation....................................................................... 486 Pump Separation............................................................................................... 486 Disassembly................................................................................................... 487 Assembly...................................................................................................... 493 HYDROSTATIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC).............................................................. 501 Pump Controller Removal And Installation...................................................................... 501 Hydrostatic Pump Calibration.................................................................................. 504 Removal And Installation...................................................................................... 509 Parts Identification (Right Half)............................................................................. 511 Parts Identification (Left Half).............................................................................. 513 System Check Relief Valves (High Pressure Relief, Charge Check & By-Pass Valve)............................... 515 Charge Relief Valve........................................................................................... 516 Pump Separation............................................................................................... 518 Shaft Seal And Shaft Replacement.............................................................................. 519 Shaft Seal And Shaft Installation............................................................................. 521 Charge Pump Removal........................................................................................... 523 Charge Pump Inspection........................................................................................ 525 Charge Pump Installation...................................................................................... 526 Disassembly................................................................................................... 528 Inspection.................................................................................................... 535 Assembly...................................................................................................... 539 Pump Neutral Adjustment....................................................................................... 548 Pump Controller Neutral Adjustment............................................................................ 551 DRIVE BELT........................................................................................................ 555 Shield Removal And Installation............................................................................... 555 Adjustment.................................................................................................... 555 Replacement................................................................................................... 555 Tensioner Pulley Removal And Installation..................................................................... 556 Tensioner Pulley Tension Spring............................................................................... 558 OIL COOLER (SEAL TO CONNECT) (STC)................................................................................ 559 Hydraulic Oil Cooler Removal And Installation................................................................. 559 DRIVE SYSTEM.......................................................................................................... 561 BRAKE............................................................................................................. 563 Switch Operated Parking Brake................................................................................. 563 Block Removal And Installation................................................................................ 563 Block Disassembly And Assembly................................................................................ 564 DRIVE COMPONENTS.................................................................................................. 565 Track Checking................................................................................................ 565 Track Adjustment.............................................................................................. 566 Track Removal And Installation................................................................................ 567 Track Idler (Front) End Play Specifications................................................................... 569 Track Idler (Front) Removal And Installation.................................................................. 569 Track Idler (Front) Parts Identification (Early Version)...................................................... 572 Track Idler (Front) Identification............................................................................ 573 Track Idler (Front) Disassembly (Early Version)............................................................... 574 Track Idler (Front) Assembly (Early Version).................................................................. 575 Track Idler (Rear) End Play Specifications.................................................................... 578 Track Idler (Rear) Parts Identification (Early Version)....................................................... 578 Track Idler (Rear) Removal And Installation................................................................... 578 Track Idler (Rear) Identification............................................................................. 579 Track Idler (Rear) Disassembly (Early Version)................................................................ 580 Track Idler (Rear) Assembly (Early Version)................................................................... 582 Track Roller Assembly End Play Specifications................................................................. 583 Track Roller Removal And Installation......................................................................... 583 Track Roller Parts Identification (Early Version)............................................................. 583 Track Roller Identification................................................................................... 584 Track Roller Disassembly (Early Version)...................................................................... 585 Track Roller Assembly (Early Version)......................................................................... 586 Track Housing Removal And Installation........................................................................ 588 Track Damage Identification................................................................................... 589 MAIN FRAME............................................................................................................ 599 SEAT BAR.......................................................................................................... 603 Removal And Installation...................................................................................... 603 Assembling Components......................................................................................... 604 Compression Spring Disassembly And Assembly................................................................... 605 OPERATOR CAB...................................................................................................... 607 Gas Cylinder Removal And Installation......................................................................... 607 Gas Cylinder Bracket Disassembly And Assembly................................................................. 609 Removal And Installation...................................................................................... 609 OPERATOR SEAT..................................................................................................... 613 Removal And Installation...................................................................................... 613 Slide Rail Removal And Installation........................................................................... 614 Seat Belt Removal And Installation............................................................................ 614 Cushion Removal And Installation.............................................................................. 615 Back Removal And Installation................................................................................. 616 Shock Removal And Installation................................................................................ 616 3-Point Seat Belt Removal And Installation.................................................................... 617 BOB-TACH.......................................................................................................... 619 Removal And Installation...................................................................................... 619 Bob-Tach Lever And Wedge...................................................................................... 621 POWER BOB-TACH.................................................................................................... 623 Removal And Installation...................................................................................... 623 Power Bob-Tach Lever And Wedge................................................................................ 625 Pivot Pin Bushing And Seal Replacement........................................................................ 627 LIFT ARMS......................................................................................................... 629 Stabilizer Bar Removal And Installation....................................................................... 629 Link Removal And Installation................................................................................. 630 Removal And Installation...................................................................................... 631 Installation Of Lift Arms..................................................................................... 633 REAR GRILL........................................................................................................ 635 Removal And Installation...................................................................................... 635 REAR DOOR......................................................................................................... 637 Removal And Installation...................................................................................... 637 Striker Removal and Installation.............................................................................. 638 Striker Disassembly and Assembly.............................................................................. 638 Door Latch and Catch Adjustment............................................................................... 638 Latch Removal And Installation................................................................................ 639 FUEL TANK......................................................................................................... 641 Removal And Installation...................................................................................... 641 Fuel Level Sender............................................................................................. 643 CONTROL PEDALS.................................................................................................... 645 Removal And Installation...................................................................................... 645 Pedal Adjustment.............................................................................................. 645 CONTROL PEDALS (ACS).............................................................................................. 647 Foot Sensor Removal And Installation.......................................................................... 647 Foot Pedal Removal And Installation........................................................................... 648 Foot Pedal Linkage Disassembly And Assembly................................................................... 648 CONTROL PANEL (NON-ADJUSTABLE PINTLES)............................................................................ 649 Removal And Installation...................................................................................... 649 Shock Removal And Installation................................................................................ 651 Shaft Removal And Installation................................................................................ 651 Shaft Disassembly And Assembly................................................................................ 651 Linkage Removal And Installation.............................................................................. 653 Linkage Neutral Adjustment.................................................................................... 656 CONTROL PANEL (ADJUSTABLE PINTLES)................................................................................ 663 Description................................................................................................... 663 Removal And Installation...................................................................................... 664 Shock Removal And Installation................................................................................ 666 Shaft Removal And Installation................................................................................ 666 Shaft Disassembly And Assembly................................................................................ 667 Linkage Removal And Installation.............................................................................. 668 Pintle Arm Disassembly and Assembly........................................................................... 673 Linkage Neutral Adjustment.................................................................................... 674 Linkage Travel Adjustment..................................................................................... 678 CONTROL PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)................................................................. 683 Removal And Installation...................................................................................... 683 CONTROL HANDLE.................................................................................................... 687 Lever Removal And Installation................................................................................ 687 Steering Lever Boot........................................................................................... 687 CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROL....................................... 689 Components Identification..................................................................................... 689 Handle Sensor Removal And Installation........................................................................ 689 Control Handle Removal And Installation....................................................................... 692 Control Handle Disassembly And Assembly....................................................................... 693 Control Lever Removal And Installation........................................................................ 694 Control Lever Boot............................................................................................ 695 CONTROL HANDLE (SELECTABLE JOYSTICK CONTROL) (SJC)................................................................ 697 Joystick Testing (Right & Left)............................................................................... 697 Joystick Removal (Right & Left)............................................................................... 698 Joystick Boot Removal (Right & Left).......................................................................... 699 Lever Assembly Removal (Right & Left)......................................................................... 699 INSIDE ACCESS PANEL............................................................................................... 701 Removal And Installation (Left)............................................................................... 701 Removal And Installation (Right).............................................................................. 701 INSIDE ACCESS PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)........................................................... 703 Panel Removal (Right)......................................................................................... 703 Panel Removal (Left).......................................................................................... 706 ELECTRICAL SYSTEM & ANALYSIS.......................................................................................... 707 ELECTRICAL SCHEMATICS............................................................................................. 711 ELECTRICAL SYSTEM INFORMATION..................................................................................... 719 Troubleshooting............................................................................................... 721 Description................................................................................................... 722 Fuse Location................................................................................................. 724 Relay Switch Location......................................................................................... 724 Solenoid Test................................................................................................. 725 BATTERY........................................................................................................... 727 Removal And Installation...................................................................................... 727 Servicing The Electrical System............................................................................... 729 Using A Booster Battery (Jump Starting)....................................................................... 730 ALTERNATOR........................................................................................................ 731 Adjusting The Alternator Belt................................................................................. 731 Alternator Identification..................................................................................... 731 Charging System Check......................................................................................... 732 Alternator Voltage Test....................................................................................... 733 Low Voltage Test.............................................................................................. 733 High Voltage Test............................................................................................. 734 Removal And Installation...................................................................................... 734 Rectifier Continuity (Diode) Test............................................................................. 735 Alternator Regulator Test..................................................................................... 736 Disassembly................................................................................................... 737 Stator Continuity Test........................................................................................ 737 Stator Ground Test............................................................................................ 737 Rotor Continuity Test......................................................................................... 738 Rotor Ground Test............................................................................................. 738 Assembly...................................................................................................... 738 STARTER........................................................................................................... 739 Checking...................................................................................................... 739 Removal And Installation...................................................................................... 740 Parts Identification.......................................................................................... 741 Disassembly And Assembly...................................................................................... 742 Inspection And Repair......................................................................................... 745 No Load Test.................................................................................................. 748 INSTRUMENT PANEL.................................................................................................. 749 Left Panel.................................................................................................... 749 Right Panel (Standard) (With Key Switch)...................................................................... 750 Right Panel (Deluxe) (With Keyless Start)..................................................................... 751 Right Panel Setup Display Options (Deluxe).................................................................... 753 Deluxe Panel Setup............................................................................................ 754 Passwords (Deluxe)............................................................................................ 754 Option And Field Accessory Panels (If Equipped)............................................................... 756 Standard Panel Removal And Installation (Right Side).......................................................... 757 Deluxe Panel Removal And Installation (Right Side)............................................................ 758 Standard & Deluxe Panel Removal And Installation (Left Side).................................................. 759 Front Accessory Panel Removal And Installation................................................................ 760 LIGHTS............................................................................................................ 761 Front Removal And Installation................................................................................ 761 Rear Removal And Installation................................................................................. 761 BOBCAT CONTROLLER................................................................................................. 764 Identification Chart.......................................................................................... 764 Removal And Installation...................................................................................... 766 CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC).................................................................... 767 Removal....................................................................................................... 767 Identification Chart.......................................................................................... 770 SPEED SENSOR (SELECTABLE JOYSTICK CONTROL) (SJC).................................................................. 773 Testing....................................................................................................... 773 Removal....................................................................................................... 774 DIAGNOSTICS SERVICE CODES......................................................................................... 777 Display....................................................................................................... 777 Number Codes List............................................................................................. 778 BICS™ SYSTEM...................................................................................................... 783 Inspecting The BICS™ Controller (Engine STOPPED - Key ON)..................................................... 783 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON).......................... 783 Inspecting The Seat Bar Sensor (Engine RUNNING)............................................................... 783 Inspecting The Traction Lock (Engine RUNNING)................................................................. 783 Inspecting The Lift Arm By-Pass Control....................................................................... 784 Additional Inspection For Loaders With Advanced Controls System (ACS) or Selectable Joystick Control (SJC).... 784 Troubleshooting............................................................................................... 785 Troubleshooting Guide......................................................................................... 786 SEAT BAR SENSOR................................................................................................... 787 Troubleshooting Chart......................................................................................... 787 Test.......................................................................................................... 788 Removal And Installation...................................................................................... 789 BICS™ Circuit Test............................................................................................ 790 TRACTION LOCK..................................................................................................... 791 Troubleshooting Chart......................................................................................... 791 Description Of The Control System............................................................................. 792 Inspecting The Control System................................................................................. 792 Parking Brake Solenoid Removal And Installation............................................................... 793 ADVANCED CONTROL SYSTEM (ACS)..................................................................................... 795 Components Identification..................................................................................... 795 Troubleshooting Guide......................................................................................... 797 Controller, Connector And Wire Identification................................................................. 798 ACS Controller Removal And Installation....................................................................... 799 Handle Sensor Connector....................................................................................... 800 Switch Handle Removal......................................................................................... 801 Switch Handle Installation.................................................................................... 803 Actuators Disassembly And Assembly............................................................................ 806 Handle Lock Solenoid Removal And Installation................................................................. 807 Handle Lock Solenoid Disassembly And Assembly................................................................. 808 Handle Lock Solenoid Connector................................................................................ 808 Foot Sensor Disassembly And Assembly.......................................................................... 809 Foot Sensor Connector......................................................................................... 810 Foot Lock Solenoid Removal And Installation................................................................... 811 Foot Lock Solenoid Connector.................................................................................. 812 ELECTRICAL/HYDRAULIC CONTROLS REFERENCE........................................................................... 813 Controls Identification Chart................................................................................. 813 ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (selectable JOYstick control) (sjc)....................................... 815 Controls Identification Chart................................................................................. 815 SERVICE PC (LAPTOP COMPUTER)...................................................................................... 819 Connecting The Service PC To Remote Start Tool................................................................ 819 CALIBRATION....................................................................................................... 821 Lift and Tilt Calibration Procedure (Selectable Joystick Control) (SJC)....................................... 821 Hydrostatic Pump Calibration (Selectable Joystick Control) (SJC).............................................. 823 Calibration Procedure (Advanced Control System) (ACS)......................................................... 828 FLYWHEEL RPM SENSOR............................................................................................... 831 Adjustment.................................................................................................... 831 ENGINE SERVICE........................................................................................................ 833 TROUBLESHOOTING................................................................................................... 837 Chart......................................................................................................... 837 ENGINE SPEED CONTROL.............................................................................................. 839 Removal And Installation...................................................................................... 839 Speed Control Cable........................................................................................... 840 ENGINE SPEED CONTROL (SELECTABLE JOYSTICK CONTROL) (SJC).......................................................... 843 Removal....................................................................................................... 843 Disassembly................................................................................................... 845 Speed Control Cable........................................................................................... 846 MUFFLER........................................................................................................... 847 Removal And Installation...................................................................................... 847 AIR CLEANER....................................................................................................... 849 Housing Removal And Installation.............................................................................. 849 RADIATOR.......................................................................................................... 851 Removal And Installation...................................................................................... 851 Mount Removal (Early Loaders)................................................................................. 853 Mount Removal (Later Loaders)................................................................................. 853 COOLING FAN....................................................................................................... 855 Drive Tension Pulley Removal And Installation................................................................. 855 Gearbox/Blower Housing Removal And Installation............................................................... 856 Blower Removal And Installation............................................................................... 857 Gearbox Parts Identification.................................................................................. 859 Gearbox Disassembly........................................................................................... 860 Gearbox Assembly.............................................................................................. 865 Gearbox, Checking Backlash.................................................................................... 870 ENGINE............................................................................................................ 873 Removal And Installation...................................................................................... 873 Mount Replacement............................................................................................. 880 Removal And Installation Tools................................................................................ 881 FLYWHEEL AND HOUSING.............................................................................................. 883 Flywheel Removal And Installation............................................................................. 883 Ring Gear Removal And Installation............................................................................ 883 Flywheel Housing Removal And Installation..................................................................... 883 RECONDITIONING THE ENGINE......................................................................................... 885 Engine Tools Identification Chart............................................................................. 885 Compression Pressure.......................................................................................... 890 Cylinder Head Clearance....................................................................................... 890 Valve Cover, Injector Nozzle And Seal Removal And Installation................................................ 891 Checking Nozzle Injection Pressure............................................................................ 893 Nozzle Spraying Condition..................................................................................... 894 Valve Seat Tightness.......................................................................................... 894 Rocker Arm And Push Rod Disassembly And Assembly.............................................................. 895 Valve Clearance............................................................................................... 895 Cylinder Head And Tappet Disassembly And Assembly............................................................. 896 Selecting Cylinder Head Gasket Disassembly And Assembly....................................................... 897 Valve Disassembly And Assembly................................................................................ 899 Engine Timing (TDC)........................................................................................... 899 Injection Pump Housing Removal................................................................................ 900 Injection Pump Governor Housing Removal And Installation...................................................... 903 Injection Pump Governor Fork Lever Removal And Installation................................................... 905 Injection Pump Governor Lever Removal And Installation........................................................ 905 Injection Pump Stop Lever Removal And Installation............................................................ 906 Injection Pump Fuel Camshaft And Governor Weight Removal And Installation..................................... 906 Injection Pump Removal and Installation....................................................................... 908 Injection Pump Housing Installation........................................................................... 915 Injection Pump Timing......................................................................................... 918 Fan Drive Pulley Disassembly And Assembly..................................................................... 920 Water Pump Disassembly And Assembly........................................................................... 921 Oil Cooler And Water Pipe Disassembly And Assembly............................................................ 921 Gearcase Cover Disassembly And Assembly....................................................................... 922 Idle Gear And Camshaft Disassembly And Assembly............................................................... 923 Oil Pan And Oil Strainer Disassembly And Assembly............................................................. 923 Connecting Rod Cap Disassembly And Assembly................................................................... 924 Piston Disassembly And Assembly............................................................................... 924 Piston Ring And Connecting Rod Disassembly And Assembly....................................................... 925 Flywheel And Crankshaft Disassembly And Assembly.............................................................. 926 Bearing Case Cover Disassembly And Assembly................................................................... 927 Flywheel Housing Disassembly And Assembly..................................................................... 928 Crankcase No. 2 Disassembly And Assembly...................................................................... 928 Crankcase No. 1 And No. 2 Disassembly And Assembly............................................................ 929 Crankshaft Disassembly And Assembly........................................................................... 929 Cylinder Head Surface Flatness................................................................................ 930 Cylinder Head Flaw............................................................................................ 931 Valve Recessing............................................................................................... 931 Valve Lapping................................................................................................. 932 Clearance Between Valve Stem And Valve Guide.................................................................. 932 Replacing Valve Guide......................................................................................... 933 Correcting Valve And Valve Seat............................................................................... 933 Free Length And Tilt Of Valve Spring.......................................................................... 934 Valve Spring Setting Load..................................................................................... 934 Oil Clearance Between Rocker Arm Shaft And Bearing............................................................ 935 Oil Clearance Between Tappet And Tappet Guide Bore............................................................ 935 Timing Gear Backlash.......................................................................................... 936 Idler Gear Side Clearance..................................................................................... 936 Camshaft Side Clearance....................................................................................... 937 Camshaft Alignment............................................................................................ 937 Cam Height.................................................................................................... 937 Oil Clearance Between Idler Gear Shaft And Idler Gearing Bushing.............................................. 938 Replacing Idler Gear Bushing.................................................................................. 939 Piston Pin Bore I.D........................................................................................... 940 Oil Clearance Between Piston Pin And Small End Bushing........................................................ 940 Replacing Small End Bushing................................................................................... 941 Clearance Between Piston Ring And Groove...................................................................... 941 Piston Ring Gap............................................................................................... 942 Connecting Rod Alignment...................................................................................... 942 Crankshaft Side Clearance..................................................................................... 943 Crankshaft Alignment.......................................................................................... 944 Oil Clearance Between Crankpin And Crankpin Bearing........................................................... 944 Oil Clearance Between Crankshaft Journal And Crankshaft Bearing............................................... 946 Replacing Crankshaft Sleeve................................................................................... 947 Cylinder Bore I.D............................................................................................. 947 Correcting Cylinder (Oversize +0.5 mm)........................................................................ 948 Engine Oil Pressure........................................................................................... 948 Rotor Lobe Clearance.......................................................................................... 949 Clearance Between Outer Rotor And Pump Body................................................................... 949 Clearance Between Rotor And Cover............................................................................. 949 Relief Valve.................................................................................................. 950 Thermostat Valve Opening Temperature.......................................................................... 950 Radiator Water Leakage........................................................................................ 950 Radiator Cap Air Leakage...................................................................................... 951 Thermostat Assembly........................................................................................... 951 Intake Air Heater............................................................................................. 952 Air Cleaner, Intake Pipe, Inlet Pipe And Muffler.............................................................. 953 Oil Pipe...................................................................................................... 953 Turbocharger.................................................................................................. 954 HEATING, VENTILATION, AIR CONDITIONING................................................................................ 955 AIR CONDITIONING SYSTEM FLOW...................................................................................... 958 Principals.................................................................................................... 958 Chart......................................................................................................... 959 COMPONENTS........................................................................................................ 961 Identification................................................................................................ 961 SAFETY............................................................................................................ 965 Safety Equipment.............................................................................................. 965 REGULAR MAINTENANCE............................................................................................... 967 Filter Elements Removal And Installation...................................................................... 967 Compressor Drive Belt Inspection.............................................................................. 968 Cleaning The Condenser........................................................................................ 969 BASIC TROUBLESHOOTING............................................................................................. 971 Poor A/C Performance.......................................................................................... 971 Cleaning The A/C Evaporator Coil & Heater Coil................................................................ 972 Compressor Drive Belt Inspection.............................................................................. 972 Checking The Electrical System................................................................................ 973 Engine Coolant By-Passing The Heater Valve.................................................................... 981 Heater Valve Not Opening Or Closing........................................................................... 982 GENERAL AIR CONDITIONING SERVICE GUIDELINES....................................................................... 983 Compressor Oil................................................................................................ 983 Compressor Oil Check.......................................................................................... 984 Component Replacement And Refrigeration Leaks................................................................. 985 SYSTEM TROUBLESHOOTING CHART...................................................................................... 987 Gauge Pressure Related Troubleshooting........................................................................ 988 Troubleshooting Tree.......................................................................................... 990 TEMPERATURE/PRESSURE.............................................................................................. 995 Chart......................................................................................................... 995 AIR CONDITIONING SERVICE.......................................................................................... 997 Chart......................................................................................................... 997 SYSTEM CHARGING AND RECLAMATION................................................................................... 999 Reclamation Procedure......................................................................................... 999 Charging Procedure With A Manifold Gauge Set..................................................................1001 Charging Procedure............................................................................................1002 COMPRESSOR........................................................................................................1005 Removal And Installation......................................................................................1005 Compressor Clutch Disassembly.................................................................................1006 CONDENSER.........................................................................................................1011 Removal And Installation......................................................................................1011 RECEIVER/DRIER....................................................................................................1013 Removal And Installation......................................................................................1013 PRESSURE RELIEF VALVE.............................................................................................1015 Removal And Installation......................................................................................1015 PRESSURE SWITCH...................................................................................................1017 Removal And Installation......................................................................................1017 EVAPORATOR/HEATER UNIT............................................................................................1019 Removal And Installation......................................................................................1019 Disassembly And Assembly......................................................................................1020 THERMOSTAT........................................................................................................1021 Removal And Installation......................................................................................1021 EXPANSION VALVE...................................................................................................1023 Removal And Installation......................................................................................1023 EVAPORATOR........................................................................................................1025 Removal And Installation......................................................................................1025 HEATER COIL.......................................................................................................1027 Removal And Installation With A/C.............................................................................1027 Removal And Installation Without A/C..........................................................................1028 BLOWER FAN........................................................................................................1031 Removal And Installation......................................................................................1031 Disassembly And Assembly......................................................................................1032 Wire Connector Removal and Installation.......................................................................1034 HEATER VALVE......................................................................................................1037 Removal and Installation......................................................................................1037 Disassembly And Assembly......................................................................................1038 SPECIFICATIONS........................................................................................................1041 LOADER SPECIFICATIONS (T300)......................................................................................1043 Machine Dimensions............................................................................................1043 Performance...................................................................................................1044 Controls......................................................................................................1044 Engine........................................................................................................1044 Hydraulic System..............................................................................................1045 Electrical....................................................................................................1046 Drive System..................................................................................................1046 Capacities....................................................................................................1046 Tracks........................................................................................................1046 ENGINE SPECIFICATIONS.............................................................................................1047 General.......................................................................................................1047 Fuel System...................................................................................................1047 Valve And Valve Timing........................................................................................1047 Valve Spring..................................................................................................1048 Piston And Piston Ring........................................................................................1048 Connecting Rod................................................................................................1048 Cylinder Head.................................................................................................1049 Crankshaft....................................................................................................1049 Cylinder Bore.................................................................................................1049 Oil Pump......................................................................................................1049 Rocker Arm....................................................................................................1050 Tappet........................................................................................................1050 Camshaft......................................................................................................1050 Thermostat....................................................................................................1050 Timing Gear...................................................................................................1051 Intake Air Heater.............................................................................................1051 Turbocharger Compressor Shaft.................................................................................1051 TORQUE SPECIFICATIONS FOR BOLTS...................................................................................1053 Torque For General SAE Bolts..................................................................................1053 Torque For General Metric Bolts...............................................................................1054 Torque For Kubota Metric Engine Bolts.........................................................................1055 Tightening Torques For General Use Screws, Bolts And Nuts.....................................................1055 HYDRAULIC CONNECTION SPECIFICATIONS...............................................................................1057 O-ring Face Seal Connection...................................................................................1057 Straight Thread O-ring Fitting................................................................................1058 Tubelines And Hoses...........................................................................................1058 Flare Fitting.................................................................................................1058 O-ring Flare Fitting..........................................................................................1059 Port Seal Fitting.............................................................................................1061 HYDRAULIC FLUID SPECIFICATIONS....................................................................................1063 Specifications................................................................................................1063 CONVERSIONS.......................................................................................................1065 Decimal And Millimeter Equivalents............................................................................1065 SMR...................................................................................................................1067 T300-1............................................................................................................1067 T300-2............................................................................................................1069 T300-3............................................................................................................1071 T300-4............................................................................................................1073 T300-5............................................................................................................1075
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