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Bobcat T300 Turbo & T300 Turbo High Flow Service Manual 2006 – Instant PDF

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Complete 1,074-page Bobcat T300 Turbo and T300 Turbo High Flow Service Manual (Doc 6902726, 2006). Covers engine, hydraulics, hydrostatics, electrical, main frame, HVAC, and full specifications. Instant PDF download.

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Description

The Bobcat T300 Turbo & T300 Turbo High Flow Service Manual is the complete workshop reference for these compact track loaders, published under document number 6902726 with the final revision dated 23 March 2006. Across 1,074 pages, this guide delivers the servicing, adjustment, removal, installation, disassembly and assembly procedures a loader mechanic needs to keep a T300 running correctly. Coverage spans every major system β€” from the Kubota V3300-DI-T turbocharged diesel engine to the hydrostatic drive, hydraulic control valve, and electrical BICSβ„’ system.

File Details

  • Manual Type: Service Manual (Workshop Manual)
  • Brand: Bobcat
  • Models Covered: T300 Turbo, T300 Turbo High Flow
  • Document Number: 6902726
  • Revision: Revision 4, dated 23 March 2006 (original print October 2003)
  • Serial Number Coverage: S/N 525411001 & Above; S/N 525511001 & Above
  • Language: English
  • Page Count: 1,074 pages
  • File Format: PDF

Chapters Covered

The Bobcat T300 Turbo & T300 Turbo High Flow Service Manual is organized into the following major sections:

  • Safety & Maintenance β€” lift arm support device, lifting and blocking the loader, operator cab raising/lowering, remote start, service schedule, lubricating the loader, towing, transporting, and the full maintenance safety protocol.
  • Hydraulic System β€” hydraulic control valve (multiple casting versions for foot control, ACS, and SJC), hydraulic pumps (standard, charge, high flow, SJC variants), lift/tilt/power Bob-Tach cylinders, lift arm by-pass control valve, rear auxiliary diverter, bucket position valve, hydraulic/hydrostatic filter, fluid reservoir, front auxiliary coupler block, and power Bob-Tach block.
  • Hydrostatic System β€” hydrostatic pump and motor (including SJC versions), charge pressure testing and setting, drive belt, oil cooler (STC), replenishing valve function, and full disassembly/assembly/inspection procedures.
  • Drive System β€” brake block and switch-operated parking brake, track checking and adjustment, track removal and installation, front and rear track idlers, track rollers, track housing, and track damage identification.
  • Main Frame β€” Bob-Tach and Power Bob-Tach, lift arms, operator cab, operator seat, seat bar and seat bar sensor, control handles (standard, ACS, and SJC), control panels, control pedals, fuel tank, rear door, rear grill, inside access panels.
  • Electrical System & Analysis β€” BICSβ„’ system, Bobcat Controller, SJC controller, ACS, instrumentation panel (Standard and Deluxe), starter, alternator, battery, lights, seat bar sensor, traction lock, diagnostics service codes, flywheel RPM sensor, speed sensor, service PC connection, and full wiring schematics.
  • Engine Service β€” Kubota V3300-DI-T engine, engine speed control, cooling fan and gearbox, air cleaner, radiator, muffler, flywheel and housing, and complete reconditioning procedures (cylinder head, crankshaft, camshaft, pistons, injection pump, turbocharger, and more).
  • Heating, Ventilation & Air Conditioning β€” compressor, condenser, receiver/drier, pressure relief valve, pressure switch, evaporator, heater unit, expansion valve, thermostat, heater coil, heater valve, blower fan, A/C service guidelines, system charging and reclamation, and troubleshooting charts.
  • Specifications β€” loader specifications, engine specifications, torque specifications for bolts, hydraulic connection specifications, hydraulic fluid specifications, and conversions.

What This Manual Delivers

This Bobcat T300 Turbo & T300 Turbo High Flow Service Manual is not a generic overview β€” it is the same service documentation used by professional Bobcat technicians to diagnose, repair, and maintain the T300 platform. Every procedure is written for the machine mechanic, with step-by-step instructions, torque values, pressure specifications, and exploded-view illustrations throughout. The manual covers multiple control configurations, including the Advanced Control System (ACS) and Selectable Joystick Control (SJC), so you can work on virtually any T300 Turbo or T300 Turbo High Flow built within the serial number ranges listed.

Key systems are documented in exceptional depth. The hydraulic section alone runs to hundreds of pages, covering every valve, pump, cylinder, and filter with disassembly, assembly, cleaning, and inspection steps. The electrical section includes complete wiring schematics for multiple loader configurations β€” without option, with ACS, and with SJC β€” alongside the full list of diagnostics service codes so you can trace faults quickly. The engine service section takes you from routine maintenance through complete engine reconditioning, with the exact Kubota specifications needed for a correct rebuild.

Coverage & Compatibility

This service manual applies to Bobcat T300 Turbo and T300 Turbo High Flow loaders with serial numbers S/N 525411001 & Above and S/N 525511001 & Above. The document is a consolidated manual covering both standard and high-flow variants, and it addresses the different hydraulic control valve castings, hydrostatic pump configurations, and control handle options that were produced across these serial ranges. Whether your machine is a standard foot-control T300 Turbo, an ACS-equipped unit, or an SJC-equipped T300 Turbo High Flow, the relevant procedures and specifications are inside.

Engine & Systems Overview

The T300 Turbo and T300 Turbo High Flow are powered by the Kubota V3300-DI-T four-cylinder turbocharged diesel engine, rated at 80.8 HP (60.3 kW) at 2400 RPM with a maximum governed speed of 2600 RPM. This manual documents the complete engine service procedures, including the fuel system, cooling system, lubrication system, intake air heater, turbocharger, injection pump, and all internal engine components. The hydrostatic drive system, hydraulic system, and electrical system are covered with the same depth, making this a true single-source reference for the entire machine.

Your Complete Bobcat T300 Turbo Service Reference

With the Bobcat T300 Turbo & T300 Turbo High Flow Service Manual on hand, you can confidently tackle everything from routine maintenance and fluid changes to major component rebuilds and system diagnostics. Correct procedures and accurate specifications matter β€” an incorrect torque value, a missed O-ring, or a misadjusted relief valve can lead to expensive damage or unsafe operation. This manual gives you the information to do the job right the first time.

Complete PDF Bookmark Tree

Complete Bookmarks

The complete bookmarks in the β€œBobcat T300 Turbo & T300 Turbo High Flow Service Manual 2006 – Instant PDF” are as follows:

MAINTENANCE SAFETYp. 3
ALPHABETICAL INDEXp. 5
CONTENTSp. 7
FOREWORDp. 8
SAFETY INSTRUCTIONSp. 11
Fire Preventionp. 13
SERIAL NUMBER LOCATIONp. 15
Loader Serial Numberp. 15
Engine Serial Numberp. 15
DELIVERY REPORTp. 16
LOADER IDENTIFICATIONp. 17
SAFETY AND MAINTENANCEp. 19
LIFTING AND BLOCKING THE LOADERp. 21
Procedurep. 21
LIFT ARM SUPPORT DEVICEp. 23
Installing The Lift Arm Support Devicep. 23
Removing The Lift Arm Support Devicep. 24
OPERATOR CABp. 25
Descriptionp. 25
Raising The Operator Cabp. 25
Lowering The Operator Cabp. 26
Emergency Exitp. 26
TRANSPORTING THE BOBCAT LOADERp. 29
Procedurep. 29
TOWING THE LOADERp. 31
Procedurep. 31
REMOTE STARTp. 33
Procedure For Loader W/O Attachments Control Harnessp. 33
Procedure For Loader With Attachments Control Harnessp. 34
Procedurep. 35
SERVICE SCHEDULEp. 37
Chartp. 37
AIR CLEANER SERVICEp. 39
Replacing Filter Elementp. 39
ENGINE COOLING SYSTEMp. 41
Cleaning Cooling Systemp. 41
Checking The Coolant Levelp. 43
Adding The Coolantp. 44
FUEL SYSTEMp. 45
Fuel Specificationsp. 45
Filling The Fuel Tankp. 45
Fuel Filterp. 46
Removing Air From The Fuel Systemp. 46
ENGINE LUBRICATION SYSTEMp. 47
Checking Engine Oilp. 47
Oil Chartp. 47
Replacing Oil And Filterp. 47
HYDRAULIC/HYDROSTATIC SYSTEMp. 49
Checking And Adding Fluidp. 49
Hydraulic Fluid Chartp. 49
Hydraulic/Hydrostatic Filter Replacementp. 50
Replacing Hydraulic Fluid And Case Drain Filtersp. 51
FAN GEARBOXp. 53
Checking And Adding Oilp. 53
POWER BOB-TACHp. 55
Inspection And Maintenancep. 55
BOB-TACHp. 57
Inspection And Maintenancep. 57
POWER BOB-TACHp. 59
Inspection And Maintenancep. 59
LUBRICATING THE LOADERp. 61
Procedurep. 61
HYDRAULIC SYSTEMp. 65
HYDRAULIC/HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATIONp. 89
Troubleshootingp. 93
Tightening Procedurep. 94
CYLINDER (LIFT)p. 95
Checkingp. 95
Removal And Installationp. 95
Parts Identificationp. 97
Disassemblyp. 98
Assemblyp. 99
CYLINDER (TILT)p. 103
Checkingp. 103
Removal And Installationp. 103
Base Pin Removal And Installationp. 105
Parts Identificationp. 106
Disassemblyp. 107
Assemblyp. 108
CYLINDER (POWER BOB-TACH)p. 111
Checkingp. 111
Removal And Installationp. 112
Parts Identificationp. 113
Disassemblyp. 114
Assemblyp. 115
MAIN RELIEF VALVEp. 119
Checking Main Reliefp. 119
Adjustmentp. 121
Removal and Installationp. 122
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (FOOT CONTROL)p. 123
Identificationp. 123
Removal And Installationp. 123
BICSβ„’ Valve, Removal And Installationp. 127
BICSβ„’ Valve, Lift Arm By-Pass Orifice Removal And Installationp. 129
BICSβ„’ Valve, Check Valve Removal And Installationp. 130
Backslide, Lock Valve Removal And Installationp. 131
BICSβ„’ Valve, Solenoid Removal And Installationp. 132
BICSβ„’ Valve, Solenoid Testingp. 133
Identification Chartp. 134
Load Check Valvep. 135
Main Relief Valvep. 136
Port Relief Valve, Tilt Spoolp. 136
Port Relief Valve, Lift Spoolp. 137
Anti-Cavitation Valve/Port Relief Valve, Tilt Spoolp. 137
Anti-Cavitation Valve, Lift Spoolp. 138
Rubber Bootp. 138
Lift And Tilt Lock Blockp. 139
Lift Spool And Detent Removalp. 140
Lift Spool And Detent Disassemblyp. 142
Lift Spool And Detent Assemblyp. 145
Lift Spool And Detent Installationp. 149
Tilt Spool Removal And Installationp. 150
Tilt Spool Disassembly And Assemblyp. 151
Auxiliary Spool Removal And Installationp. 152
Auxiliary Plug Removal And Installationp. 154
Auxiliary Electric Solenoid Disassemblyp. 155
Port-Auxiliary Section Removal And Installationp. 156
Cleaning And Inspectionp. 156
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)p. 157
Identificationp. 157
Actuator Removal And Installation (In Loader)p. 158
Actuator Removal And Installation (Out Of Loader)p. 160
Actuator Removal And Installation (Out Of Loader) (Cont’d)p. 161
Removal And Installationp. 162
BICSβ„’ Valve, Removal And Installationp. 166
BICSβ„’ Valve, Lift Arm By-Pass Orifice Disassembly And Assemblyp. 169
BICSβ„’ Valve, Check Valve Disassembly And Assemblyp. 170
BICSβ„’ Valve, Lock Valve Disassembly And Assemblyp. 171
BICSβ„’ Valve, Solenoid Disassembly And Assemblyp. 172
BICSβ„’ Valve, Solenoid Testingp. 173
Identification Chartp. 174
Lift Base End Restrictorp. 175
Load Check Valvep. 176
Main Relief Valvep. 177
Port Relief Valvep. 179
Anti-Cavitation Valve/Port Relief Valvep. 180
Anti-Cavitation Valvep. 181
Lift Spool Removalp. 182
Lift Spool Removal And Installationp. 183
Lift and Tilt Spool Disassembly And Assemblyp. 184
Auxiliary Spool Removal And Installationp. 185
Auxiliary Electric Solenoid Disassemblyp. 186
Port-Auxiliary Section Disassemblyp. 187
Cleaning And Inspectionp. 187
HYDRAULIC CONTROL VALVE (2 PIECE CASTING) (selectable joystick control) (sjc)p. 189
Identificationp. 189
Actuator Removal And Installation (In Loader)p. 190
Actuator Removal And Installation (Out Of Loader)p. 192
Removal And Installationp. 194
BICSβ„’ Valve, Removal And Installationp. 198
BICSβ„’ Valve, Lift Arm By-Pass Orifice Disassembly And Assemblyp. 201
BICSβ„’ Valve, Check Valve Disassembly And Assemblyp. 202
BICSβ„’ Valve, Lock Valve Disassembly And Assemblyp. 203
BICSβ„’ Valve, Solenoid Disassembly And Assemblyp. 204
BICSβ„’ Valve, Solenoid Testingp. 205
Identification Chartp. 206
Lift Base End Restrictorp. 207
Load Check Valvep. 208
Main Relief Valvep. 209
Port Relief Valvep. 211
Anti-Cavitation Valve/Port Relief Valvep. 212
Anti-Cavitation Valvep. 213
Lift Spool Removalp. 214
Lift Spool Removal And Installationp. 215
Lift And Tilt Spool Disassembly And Assemblyp. 216
Auxiliary Spool Removal And Installationp. 217
Auxiliary Electric Solenoid Disassemblyp. 218
Port-Auxiliary Section Disassemblyp. 219
Cleaning And Inspectionp. 219
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (FOOT CONTROL)p. 221
Removal And Installationp. 221
Identification Chartp. 225
BICSβ„’ Valve, Lift Load Check Valve Removal And Installationp. 226
Load Check Valve Removal And Installation (Tilt & Auxiliary)p. 227
Anti-Cavitation Valve (Lift, Rod End)p. 227
Anti-Cavitation Valve (Lift, Rod End) (Cont’d)p. 228
Port Relief/Anti-Cavitation Valve (Lift, Base End)p. 228
Port Relief/Anti-Cavitation Valve (Tilt, Base End)p. 229
Port Relief/Anti-Cavitation Valve (Tilt, Rod End)p. 229
Port Relief Valvep. 230
Plug Removalp. 231
Rubber Boot Removal and Installationp. 232
End Cap/Spool Lock Block Removal and Installationp. 233
Lift Spool and Detent Removal and Installationp. 234
Auxiliary Spool Removal And Installationp. 246
Auxiliary Solenoid Disassembly and Assemblyp. 248
BICSβ„’ Valve Solenoid Disassembly And Assemblyp. 249
BICSβ„’ Valve, Lock Valve Removal And Installationp. 250
BICSβ„’ Valve, Lift Arm By-Pass Orifice Disassembly And Assemblyp. 252
Main Relief Valvep. 253
BICSβ„’ Valve, Check Valve Removal and Installationp. 254
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (ADVANCED CONTROL SYSTEM) (ACS)p. 255
Removal And Installationp. 256
Actuator Removal And Installation (In Loader)p. 260
Actuator Removal And Installation (Out of Loader)p. 262
Identification Chartp. 265
BICSβ„’ Valve, Lift Load Check Valve Removal And Installationp. 266
Load Check Valve Removal And Installation (Tilt & Auxiliary)p. 267
Anti-Cavitation Valve (Lift, Rod End)p. 267
Port Relief/Anti-Cavitation Valve (Lift, Base End)p. 268
Port Relief/Anti-Cavitation Valve (Tilt, Base End)p. 269
Port Relief/Anti-Cavitation Valve (Tilt, Rod End)p. 269
Port Relief Valvep. 270
Plug Removalp. 271
End Cap Block Removal And Installationp. 272
Lift Spool Removal And Installationp. 273
Tilt Spool Removal And Installationp. 277
Auxiliary Spool Removal And Installationp. 279
Auxiliary Solenoid Disassembly And Assemblyp. 281
BICSβ„’ Valve Solenoid Disassembly And Assemblyp. 282
BICSβ„’ Valve, Lock Valve Removal And Installationp. 283
BICSβ„’ Valve, Lock Valve Removal And Installation (Cont’d)p. 284
BICSβ„’ Valve, Lift Arm By-Pass Orifice Disassembly And Assemblyp. 285
Main Relief Valvep. 285
BICSβ„’ Valve, Check Valve Removal And Installationp. 286
HYDRAULIC CONTROL VALVE (1 PIECE CASTING) (SELECTABLE JOYSTICK CONTROL) (SJC)p. 287
Removal And Installationp. 288
Actuator Removal And Installation (In Loader)p. 292
Identification Chartp. 297
BICSβ„’ Valve, Lift Load Check Valve Removal And Installationp. 298
Load Check Valve Removal And Installation (Tilt & Auxiliary)p. 299
Anti-Cavitation Valve (Lift, Rod End)p. 299
Port Relief/Anti-Cavitation Valve (Lift, Base End)p. 300
Port Relief/Anti-Cavitation Valve (Tilt, Base End)p. 301
Port Relief/Anti-Cavitation Valve (Tilt, Rod End)p. 301
Port Relief Valvep. 302
Plug Removalp. 303
End Cap Block Removal and Installationp. 304
Lift Spool Removal and Installationp. 305
Auxiliary Spool Removal And Installationp. 311
Auxiliary Solenoid Disassembly And Assemblyp. 313
BICSβ„’ Valve Solenoid Disassembly And Assemblyp. 314
BICSβ„’ Valve, Lock Valve Removal And Installationp. 315
BICSβ„’ Valve, Lock Valve Removal And Installation (Cont’d)p. 316
BICSβ„’ Valve, Lift Arm By-Pass Orifice Disassembly And Assemblyp. 317
Main Relief Valvep. 317
BICSβ„’ Valve, Check Valve Removal And Installationp. 318
LIFT ARM BY-PASS CONTROL VALVEp. 319
Inspectingp. 319
Additional Inspection For Loaders W/Advanced Hand Controlsp. 319
Removal And Installationp. 319
Disassembly And Assemblyp. 320
HYDRAULIC PUMPp. 321
Check The Output Of The Hydraulic Pumpp. 321
Removal And Installationp. 322
Parts Identificationp. 324
Disassembly And Assemblyp. 325
HYDRAULIC PUMP (CHARGE)p. 333
Check The Output Of The Hydraulic Pumpp. 333
Removal and Installationp. 336
HYDRAULIC PUMP (HIGH FLOW)p. 337
Hydraulic Pump Test (30 GPM)p. 337
Hydraulic Pump Test (40 GPM)p. 338
Inline Hydraulic Pump Test (Standard)p. 339
Inline Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM)p. 341
High Flow Relief Adjustment Procedure (30 GPM And 40 GPM)p. 343
High Flow Relief Valve Removal And Installation (30 GPM And 40 GPM)p. 345
Removal And Installation (30 GPM And 40 GPM)p. 346
Identification (30 GPM) (S/N 525414499 & Below)p. 348
Identification (40 GPM) (S/N 525414500 & Above)p. 349
Disassembly And Assembly (30 GPM And 40 GPM)p. 350
HYDRAULIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC)p. 363
Check The Output Of The Hydraulic Pumpp. 363
Removal And Installationp. 364
Identificationp. 366
Disassembly And Assemblyp. 367
HYDRAULIC PUMP (HIGH FLOW) (SELECTABLE JOYSTICK CONTROL) (SJC)p. 373
Hydraulic Pump Test (30 GPM)p. 373
Hydraulic Pump Test (40 GPM)p. 374
Inline Hydraulic Pump Test (Standard)p. 375
Inline Hydraulic Pump Test (High Flow) (30 GPM And 40 GPM)p. 377
High Flow Relief Adjustment Procedure (30 GPM And 40 GPM)p. 379
High Flow Relief Valve Removal And Installation (30 GPM And 40 GPM)p. 381
Removal And Installation (30 GPM And 40 GPM)p. 382
Identification (30 GPM) (S/N 525414499 & Below)p. 384
Identification (40 GPM) (S/N 525414500 & Above)p. 385
Disassembly And Assembly (30 GPM And 40 GPM)p. 386
HYDRAULIC/HYDROSTATIC FILTERp. 395
Housing Removal And Installationp. 395
Mount Removal And Installationp. 396
HYDRAULIC FLUID RESERVOIRp. 397
Fluid Removalp. 397
Removal And Installationp. 397
Hydraulic Fluid Screenp. 400
BUCKET POSITION VALVEp. 401
Solenoid Removal And Installationp. 401
Solenoid Testingp. 401
Removal And Installationp. 402
Disassembly And Assemblyp. 402
REAR AUXILIARY DIVERTERp. 405
Removal And Installationp. 405
Disassembly And Assemblyp. 407
Solenoid Testingp. 412
Inspectionp. 412
POWER BOB-TACH BLOCKp. 413
Removal And Installationp. 413
Disassembly And Assemblyp. 414
FRONT AUXILIARY HYDRAULIC COUPLER BLOCKp. 419
Removal and Installationp. 419
Disassembly And Assemblyp. 419
HYDROSTATIC SYSTEMp. 421
HYDROSTATIC SYSTEM INFORMATIONp. 423
Troubleshooting Chartp. 423
Replenishing Valve Functionp. 424
HYDROSTATIC MOTORp. 425
Removal And Installationp. 425
Parts Identificationp. 428
Disassemblyp. 430
Inspectionp. 438
Assemblyp. 439
Fillingp. 447
HYDROSTATIC MOTOR (SELECTABLE JOYSTICK CONTROL) (SJC)p. 449
Removal And Installationp. 449
Parts Identificationp. 452
Disassemblyp. 454
Inspectionp. 463
Assemblyp. 464
Fillingp. 473
CHARGE PRESSUREp. 475
Testingp. 475
Removal and Installationp. 477
Setting Charge Pressurep. 478
HYDROSTATIC PUMPp. 479
Removal And Installationp. 479
Replenishing/High Pressure Relief Valvep. 481
Parts Identification (Right Half)p. 482
Parts Identification (Left Half)p. 484
Hydraulic Pump Removal And Installationp. 486
Pump Separationp. 486
Disassemblyp. 487
Assemblyp. 493
HYDROSTATIC PUMP (SELECTABLE JOYSTICK CONTROL) (SJC)p. 501
Pump Controller Removal And Installationp. 501
Hydrostatic Pump Calibrationp. 504
Removal And Installationp. 509
Parts Identification (Right Half)p. 511
Parts Identification (Left Half)p. 513
System Check Relief Valves (High Pressure Relief, Charge Check & By-Pass Valve)p. 515
Charge Relief Valvep. 516
Pump Separationp. 518
Shaft Seal And Shaft Replacementp. 519
Shaft Seal And Shaft Installationp. 521
Charge Pump Removalp. 523
Charge Pump Inspectionp. 525
Charge Pump Installationp. 526
Disassemblyp. 528
Inspectionp. 535
Assemblyp. 539
Pump Neutral Adjustmentp. 548
Pump Controller Neutral Adjustmentp. 551
DRIVE BELTp. 555
Shield Removal And Installationp. 555
Adjustmentp. 555
Replacementp. 555
Tensioner Pulley Removal And Installationp. 556
Tensioner Pulley Tension Springp. 558
OIL COOLER (SEAL TO CONNECT) (STC)p. 559
Hydraulic Oil Cooler Removal And Installationp. 559
DRIVE SYSTEMp. 561
BRAKEp. 563
Switch Operated Parking Brakep. 563
Block Removal And Installationp. 563
Block Disassembly And Assemblyp. 564
DRIVE COMPONENTSp. 565
Track Checkingp. 565
Track Adjustmentp. 566
Track Removal And Installationp. 567
Track Idler (Front) End Play Specificationsp. 569
Track Idler (Front) Removal And Installationp. 569
Track Idler (Front) Parts Identification (Early Version)p. 572
Track Idler (Front) Identificationp. 573
Track Idler (Front) Disassembly (Early Version)p. 574
Track Idler (Front) Assembly (Early Version)p. 575
Track Idler (Rear) End Play Specificationsp. 578
Track Idler (Rear) Parts Identification (Early Version)p. 578
Track Idler (Rear) Removal And Installationp. 578
Track Idler (Rear) Identificationp. 579
Track Idler (Rear) Disassembly (Early Version)p. 580
Track Idler (Rear) Assembly (Early Version)p. 582
Track Roller Assembly End Play Specificationsp. 583
Track Roller Removal And Installationp. 583
Track Roller Parts Identification (Early Version)p. 583
Track Roller Identificationp. 584
Track Roller Disassembly (Early Version)p. 585
Track Roller Assembly (Early Version)p. 586
Track Housing Removal And Installationp. 588
Track Damage Identificationp. 589
MAIN FRAMEp. 599
SEAT BARp. 603
Removal And Installationp. 603
Assembling Componentsp. 604
Compression Spring Disassembly And Assemblyp. 605
OPERATOR CABp. 607
Gas Cylinder Removal And Installationp. 607
Gas Cylinder Bracket Disassembly And Assemblyp. 609
Removal And Installationp. 609
OPERATOR SEATp. 613
Removal And Installationp. 613
Slide Rail Removal And Installationp. 614
Seat Belt Removal And Installationp. 614
Cushion Removal And Installationp. 615
Back Removal And Installationp. 616
Shock Removal And Installationp. 616
3-Point Seat Belt Removal And Installationp. 617
BOB-TACHp. 619
Removal And Installationp. 619
Bob-Tach Lever And Wedgep. 621
POWER BOB-TACHp. 623
Removal And Installationp. 623
Power Bob-Tach Lever And Wedgep. 625
Pivot Pin Bushing And Seal Replacementp. 627
LIFT ARMSp. 629
Stabilizer Bar Removal And Installationp. 629
Link Removal And Installationp. 630
Removal And Installationp. 631
Installation Of Lift Armsp. 633
REAR GRILLp. 635
Removal And Installationp. 635
REAR DOORp. 637
Removal And Installationp. 637
Striker Removal and Installationp. 638
Striker Disassembly and Assemblyp. 638
Door Latch and Catch Adjustmentp. 638
Latch Removal And Installationp. 639
FUEL TANKp. 641
Removal And Installationp. 641
Fuel Level Senderp. 643
CONTROL PEDALSp. 645
Removal And Installationp. 645
Pedal Adjustmentp. 645
CONTROL PEDALS (ACS)p. 647
Foot Sensor Removal And Installationp. 647
Foot Pedal Removal And Installationp. 648
Foot Pedal Linkage Disassembly And Assemblyp. 648
CONTROL PANEL (NON-ADJUSTABLE PINTLES)p. 649
Removal And Installationp. 649
Shock Removal And Installationp. 651
Shaft Removal And Installationp. 651
Shaft Disassembly And Assemblyp. 651
Linkage Removal And Installationp. 653
Linkage Neutral Adjustmentp. 656
CONTROL PANEL (ADJUSTABLE PINTLES)p. 663
Descriptionp. 663
Removal And Installationp. 664
Shock Removal And Installationp. 666
Shaft Removal And Installationp. 666
Shaft Disassembly And Assemblyp. 667
Linkage Removal And Installationp. 668
Pintle Arm Disassembly and Assemblyp. 673
Linkage Neutral Adjustmentp. 674
Linkage Travel Adjustmentp. 678
CONTROL PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)p. 683
Removal And Installationp. 683
CONTROL HANDLEp. 687
Lever Removal And Installationp. 687
Steering Lever Bootp. 687
CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND/FOOT CONTROLp. 689
Components Identificationp. 689
Handle Sensor Removal And Installationp. 689
Control Handle Removal And Installationp. 692
Control Handle Disassembly And Assemblyp. 693
Control Lever Removal And Installationp. 694
Control Lever Bootp. 695
CONTROL HANDLE (SELECTABLE JOYSTICK CONTROL) (SJC)p. 697
Joystick Testing (Right & Left)p. 697
Joystick Removal (Right & Left)p. 698
Joystick Boot Removal (Right & Left)p. 699
Lever Assembly Removal (Right & Left)p. 699
INSIDE ACCESS PANELp. 701
Removal And Installation (Left)p. 701
Removal And Installation (Right)p. 701
INSIDE ACCESS PANEL (SELECTABLE JOYSTICK CONTROL) (SJC)p. 703
Panel Removal (Right)p. 703
Panel Removal (Left)p. 706
ELECTRICAL SYSTEM & ANALYSISp. 707
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATIONp. 719
Troubleshootingp. 721
Descriptionp. 722
Fuse Locationp. 724
Relay Switch Locationp. 724
Solenoid Testp. 725
BATTERYp. 727
Removal And Installationp. 727
Servicing The Electrical Systemp. 729
Using A Booster Battery (Jump Starting)p. 730
ALTERNATORp. 731
Adjusting The Alternator Beltp. 731
Alternator Identificationp. 731
Charging System Checkp. 732
Alternator Voltage Testp. 733
Low Voltage Testp. 733
High Voltage Testp. 734
Removal And Installationp. 734
Rectifier Continuity (Diode) Testp. 735
Alternator Regulator Testp. 736
Disassemblyp. 737
Stator Continuity Testp. 737
Stator Ground Testp. 737
Rotor Continuity Testp. 738
Rotor Ground Testp. 738
Assemblyp. 738
STARTERp. 739
Checkingp. 739
Removal And Installationp. 740
Parts Identificationp. 741
Disassembly And Assemblyp. 742
Inspection And Repairp. 745
No Load Testp. 748
INSTRUMENT PANELp. 749
Left Panelp. 749
Right Panel (Standard) (With Key Switch)p. 750
Right Panel (Deluxe) (With Keyless Start)p. 751
Right Panel Setup Display Options (Deluxe)p. 753
Deluxe Panel Setupp. 754
Passwords (Deluxe)p. 754
Option And Field Accessory Panels (If Equipped)p. 756
Standard Panel Removal And Installation (Right Side)p. 757
Deluxe Panel Removal And Installation (Right Side)p. 758
Standard & Deluxe Panel Removal And Installation (Left Side)p. 759
Front Accessory Panel Removal And Installationp. 760
LIGHTSp. 761
Front Removal And Installationp. 761
Rear Removal And Installationp. 761
BOBCAT CONTROLLERp. 764
Identification Chartp. 764
Removal And Installationp. 766
CONTROLLER (SELECTABLE JOYSTICK CONTROL) (SJC)p. 767
Removalp. 767
Identification Chartp. 770
SPEED SENSOR (SELECTABLE JOYSTICK CONTROL) (SJC)p. 773
Testingp. 773
Removalp. 774
DIAGNOSTICS SERVICE CODESp. 777
Displayp. 777
Number Codes Listp. 778
BICSβ„’ SYSTEMp. 783
Inspecting The BICSβ„’ Controller (Engine STOPPED – Key ON)p. 783
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)p. 783
Inspecting The Seat Bar Sensor (Engine RUNNING)p. 783
Inspecting The Traction Lock (Engine RUNNING)p. 783
Inspecting The Lift Arm By-Pass Controlp. 784
Additional Inspection For Loaders With Advanced Controls System (ACS) or Selectable Joystick Control (SJC)p. 784
Troubleshootingp. 785
Troubleshooting Guidep. 786
SEAT BAR SENSORp. 787
Troubleshooting Chartp. 787
Testp. 788
Removal And Installationp. 789
BICSβ„’ Circuit Testp. 790
TRACTION LOCKp. 791
Troubleshooting Chartp. 791
Description Of The Control Systemp. 792
Inspecting The Control Systemp. 792
Parking Brake Solenoid Removal And Installationp. 793
ADVANCED CONTROL SYSTEM (ACS)p. 795
Components Identificationp. 795
Troubleshooting Guidep. 797
Controller, Connector And Wire Identificationp. 798
ACS Controller Removal And Installationp. 799
Handle Sensor Connectorp. 800
Switch Handle Removalp. 801
Switch Handle Installationp. 803
Actuators Disassembly And Assemblyp. 806
Handle Lock Solenoid Removal And Installationp. 807
Handle Lock Solenoid Disassembly And Assemblyp. 808
Handle Lock Solenoid Connectorp. 808
Foot Sensor Disassembly And Assemblyp. 809
Foot Sensor Connectorp. 810
Foot Lock Solenoid Removal And Installationp. 811
Foot Lock Solenoid Connectorp. 812
ELECTRICAL/HYDRAULIC CONTROLS REFERENCEp. 813
Controls Identification Chartp. 813
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE (selectable JOYstick control) (sjc)p. 815
Controls Identification Chartp. 815
SERVICE PC (LAPTOP COMPUTER)p. 819
Connecting The Service PC To Remote Start Toolp. 819
CALIBRATIONp. 821
Lift and Tilt Calibration Procedure (Selectable Joystick Control) (SJC)p. 821
Hydrostatic Pump Calibration (Selectable Joystick Control) (SJC)p. 823
Calibration Procedure (Advanced Control System) (ACS)p. 828
FLYWHEEL RPM SENSORp. 831
Adjustmentp. 831
ENGINE SERVICEp. 833
TROUBLESHOOTINGp. 837
Chartp. 837
ENGINE SPEED CONTROLp. 839
Removal And Installationp. 839
Speed Control Cablep. 840
ENGINE SPEED CONTROL (SELECTABLE JOYSTICK CONTROL) (SJC)p. 843
Removalp. 843
Disassemblyp. 845
Speed Control Cablep. 846
MUFFLERp. 847
Removal And Installationp. 847
AIR CLEANERp. 849
Housing Removal And Installationp. 849
RADIATORp. 851
Removal And Installationp. 851
Mount Removal (Early Loaders)p. 853
Mount Removal (Later Loaders)p. 853
COOLING FANp. 855
Drive Tension Pulley Removal And Installationp. 855
Gearbox/Blower Housing Removal And Installationp. 856
Blower Removal And Installationp. 857
Gearbox Parts Identificationp. 859
Gearbox Disassemblyp. 860
Gearbox Assemblyp. 865
Gearbox, Checking Backlashp. 870
ENGINEp. 873
Removal And Installationp. 873
Mount Replacementp. 880
Removal And Installation Toolsp. 881
FLYWHEEL AND HOUSINGp. 883
Flywheel Removal And Installationp. 883
Ring Gear Removal And Installationp. 883
Flywheel Housing Removal And Installationp. 883
RECONDITIONING THE ENGINEp. 885
Engine Tools Identification Chartp. 885
Compression Pressurep. 890
Cylinder Head Clearancep. 890
Valve Cover, Injector Nozzle And Seal Removal And Installationp. 891
Checking Nozzle Injection Pressurep. 893
Nozzle Spraying Conditionp. 894
Valve Seat Tightnessp. 894
Rocker Arm And Push Rod Disassembly And Assemblyp. 895
Valve Clearancep. 895
Cylinder Head And Tappet Disassembly And Assemblyp. 896
Selecting Cylinder Head Gasket Disassembly And Assemblyp. 897
Valve Disassembly And Assemblyp. 899
Engine Timing (TDC)p. 899
Injection Pump Housing Removalp. 900
Injection Pump Governor Housing Removal And Installationp. 903
Injection Pump Governor Fork Lever Removal And Installationp. 905
Injection Pump Governor Lever Removal And Installationp. 905
Injection Pump Stop Lever Removal And Installationp. 906
Injection Pump Fuel Camshaft And Governor Weight Removal And Installationp. 906
Injection Pump Removal and Installationp. 908
Injection Pump Housing Installationp. 915
Injection Pump Timingp. 918
Fan Drive Pulley Disassembly And Assemblyp. 920
Water Pump Disassembly And Assemblyp. 921
Oil Cooler And Water Pipe Disassembly And Assemblyp. 921
Gearcase Cover Disassembly And Assemblyp. 922
Idle Gear And Camshaft Disassembly And Assemblyp. 923
Oil Pan And Oil Strainer Disassembly And Assemblyp. 923
Connecting Rod Cap Disassembly And Assemblyp. 924
Piston Disassembly And Assemblyp. 924
Piston Ring And Connecting Rod Disassembly And Assemblyp. 925
Flywheel And Crankshaft Disassembly And Assemblyp. 926
Bearing Case Cover Disassembly And Assemblyp. 927
Flywheel Housing Disassembly And Assemblyp. 928
Crankcase No. 2 Disassembly And Assemblyp. 928
Crankcase No. 1 And No. 2 Disassembly And Assemblyp. 929
Crankshaft Disassembly And Assemblyp. 929
Cylinder Head Surface Flatnessp. 930
Cylinder Head Flawp. 931
Valve Recessingp. 931
Valve Lappingp. 932
Clearance Between Valve Stem And Valve Guidep. 932
Replacing Valve Guidep. 933
Correcting Valve And Valve Seatp. 933
Free Length And Tilt Of Valve Springp. 934
Valve Spring Setting Loadp. 934
Oil Clearance Between Rocker Arm Shaft And Bearingp. 935
Oil Clearance Between Tappet And Tappet Guide Borep. 935
Timing Gear Backlashp. 936
Idler Gear Side Clearancep. 936
Camshaft Side Clearancep. 937
Camshaft Alignmentp. 937
Cam Heightp. 937
Oil Clearance Between Idler Gear Shaft And Idler Gearing Bushingp. 938
Replacing Idler Gear Bushingp. 939
Piston Pin Bore I.D.p. 940
Oil Clearance Between Piston Pin And Small End Bushingp. 940
Replacing Small End Bushingp. 941
Clearance Between Piston Ring And Groovep. 941
Piston Ring Gapp. 942
Connecting Rod Alignmentp. 942
Crankshaft Side Clearancep. 943
Crankshaft Alignmentp. 944
Oil Clearance Between Crankpin And Crankpin Bearingp. 944
Oil Clearance Between Crankshaft Journal And Crankshaft Bearingp. 946
Replacing Crankshaft Sleevep. 947
Cylinder Bore I.D.p. 947
Correcting Cylinder (Oversize +0.5 mm)p. 948
Engine Oil Pressurep. 948
Rotor Lobe Clearancep. 949
Clearance Between Outer Rotor And Pump Bodyp. 949
Clearance Between Rotor And Coverp. 949
Relief Valvep. 950
Thermostat Valve Opening Temperaturep. 950
Radiator Water Leakagep. 950
Radiator Cap Air Leakagep. 951
Thermostat Assemblyp. 951
Intake Air Heaterp. 952
Air Cleaner, Intake Pipe, Inlet Pipe And Mufflerp. 953
Oil Pipep. 953
Turbochargerp. 954
HEATING, VENTILATION, AIR CONDITIONINGp. 955
AIR CONDITIONING SYSTEM FLOWp. 958
Principalsp. 958
Chartp. 959
COMPONENTSp. 961
Identificationp. 961
SAFETYp. 965
Safety Equipmentp. 965
REGULAR MAINTENANCEp. 967
Filter Elements Removal And Installationp. 967
Compressor Drive Belt Inspectionp. 968
Cleaning The Condenserp. 969
BASIC TROUBLESHOOTINGp. 971
Poor A/C Performancep. 971
Cleaning The A/C Evaporator Coil & Heater Coilp. 972
Compressor Drive Belt Inspectionp. 972
Checking The Electrical Systemp. 973
Engine Coolant By-Passing The Heater Valvep. 981
Heater Valve Not Opening Or Closingp. 982
GENERAL AIR CONDITIONING SERVICE GUIDELINESp. 983
Compressor Oilp. 983
Compressor Oil Checkp. 984
Component Replacement And Refrigeration Leaksp. 985
SYSTEM TROUBLESHOOTING CHARTp. 987
Gauge Pressure Related Troubleshootingp. 988
Troubleshooting Treep. 990
TEMPERATURE/PRESSUREp. 995
Chartp. 995
AIR CONDITIONING SERVICEp. 997
Chartp. 997
SYSTEM CHARGING AND RECLAMATIONp. 999
Reclamation Procedurep. 999
Charging Procedure With A Manifold Gauge Setp. 1001
Charging Procedurep. 1002
COMPRESSORp. 1005
Removal And Installationp. 1005
Compressor Clutch Disassemblyp. 1006
CONDENSERp. 1011
Removal And Installationp. 1011
RECEIVER/DRIERp. 1013
Removal And Installationp. 1013
PRESSURE RELIEF VALVEp. 1015
Removal And Installationp. 1015
PRESSURE SWITCHp. 1017
Removal And Installationp. 1017
EVAPORATOR/HEATER UNITp. 1019
Removal And Installationp. 1019
Disassembly And Assemblyp. 1020
THERMOSTATp. 1021
Removal And Installationp. 1021
EXPANSION VALVEp. 1023
Removal And Installationp. 1023
EVAPORATORp. 1025
Removal And Installationp. 1025
HEATER COILp. 1027
Removal And Installation With A/Cp. 1027
Removal And Installation Without A/Cp. 1028
BLOWER FANp. 1031
Removal And Installationp. 1031
Disassembly And Assemblyp. 1032
Wire Connector Removal and Installationp. 1034
HEATER VALVEp. 1037
Removal and Installationp. 1037
Disassembly And Assemblyp. 1038
SPECIFICATIONSp. 1041
LOADER SPECIFICATIONS (T300)p. 1043
Machine Dimensionsp. 1043
Performancep. 1044
Controlsp. 1044
Enginep. 1044
Hydraulic Systemp. 1045
Electricalp. 1046
Drive Systemp. 1046
Capacitiesp. 1046
Tracksp. 1046
ENGINE SPECIFICATIONSp. 1047
Generalp. 1047
Fuel Systemp. 1047
Valve And Valve Timingp. 1047
Valve Springp. 1048
Piston And Piston Ringp. 1048
Connecting Rodp. 1048
Cylinder Headp. 1049
Crankshaftp. 1049
Cylinder Borep. 1049
Oil Pumpp. 1049
Rocker Armp. 1050
Tappetp. 1050
Camshaftp. 1050
Thermostatp. 1050
Timing Gearp. 1051
Intake Air Heaterp. 1051
Turbocharger Compressor Shaftp. 1051
TORQUE SPECIFICATIONS FOR BOLTSp. 1053
Torque For General SAE Boltsp. 1053
Torque For General Metric Boltsp. 1054
Torque For Kubota Metric Engine Boltsp. 1055
Tightening Torques For General Use Screws, Bolts And Nutsp. 1055
HYDRAULIC CONNECTION SPECIFICATIONSp. 1057
O-ring Face Seal Connectionp. 1057
Straight Thread O-ring Fittingp. 1058
Tubelines And Hosesp. 1058
Flare Fittingp. 1058
O-ring Flare Fittingp. 1059
Port Seal Fittingp. 1061
HYDRAULIC FLUID SPECIFICATIONSp. 1063
Specificationsp. 1063
CONVERSIONSp. 1065
Decimal And Millimeter Equivalentsp. 1065
SMR
T300-1
T300-2
T300-3
T300-4


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Bobcat T300 Turbo & T300 Turbo High Flow Service Manual 2006 - Instant PDF β€” PDF page 1 preview
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Delivered as an instant PDF download, the manual is available immediately after purchase. There is no shipping, no waiting, and no physical book to keep track of. Read it on any device β€” laptop, tablet, or smartphone β€” and print only the pages you need for the shop. Whether you are a professional technician, a farm or ranch owner, or a serious DIY mechanic, this Bobcat T300 Turbo service manual is the reference that keeps your machine running.

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