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Bobcat T450 Compact Track Loader Service Manual SN B4J611001 & Above – PDF DOWNLOAD
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Bobcat T450 Compact Track Loader Service Manual SN B4J611001 & Above – PDF DOWNLOAD
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Description
Bobcat T450 Compact Track Loader Service Manual SN B4J611001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat T450 Compact Track Loader Service Manual SN B4J611001 & Above – PDF DOWNLOAD
Language : English
Pages : 889
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T450 Compact Track Loader Service Manual SN B4J611001 & Above – PDF DOWNLOAD
FOREWORD:
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS / FOPS (Including side screens) is in good condition and is not modified.
2. Check that ROPS mounting hardware is tightened and is Bobcat approved.
3. The seat belt must be correctly installed, functional and in good condition.
4. The seat bar must be correctly adjusted, clean and lubricated.
5. Check lift arm support device, replace if damaged.
6. Machine signs (decals) must be legible and in the correct location.
7. Steering levers, hand controls and foot pedals must return to neutral (as applicable).
8. Check for correct function of the work lights.
9. The parking brake must function correctly.
10. Enclosure door latches must open and close freely.
11. Bob-Tach® attachment mounting system wedges and linkages must function correctly and be in good condition.
12. Safety treads must be in good condition.
13. Check for correct function of indicator lamps.
14. Check all machine fluid levels.
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 T450 Compact Track Loader Service Manual SN B4J611001 & Above – PDF DOWNLOAD
MAINTENANCE SAFETY.............................................................................. 3 CONTENTS........................................................................................ 5 FOREWORD........................................................................................ 7 FOREWORD.................................................................................... 9 SAFETY INSTRUCTIONS......................................................................... 11 Avoid Silica Dust....................................................................... 11 FIRE PREVENTION............................................................................. 12 Maintenance............................................................................. 12 Operation............................................................................... 12 Electrical.............................................................................. 12 Hydraulic System........................................................................ 12 Fueling................................................................................. 12 Starting................................................................................ 12 Exhaust System.......................................................................... 12 Welding And Grinding.................................................................... 13 Fire Extinguishers...................................................................... 13 SERIAL NUMBER LOCATIONS..................................................................... 14 Loader Serial Number.................................................................... 14 Engine Serial Number.................................................................... 14 DELIVERY REPORT............................................................................. 15 LOADER IDENTIFICATION....................................................................... 16 SAFETY AND MAINTENANCE.......................................................................... 17 LIFTING AND BLOCKING THE LOADER............................................................. 19 Procedure............................................................................... 19 LIFT ARM SUPPORT............................................................................ 21 Description............................................................................. 21 Installing.............................................................................. 22 Removing................................................................................ 23 OPERATOR CAB................................................................................ 25 Description............................................................................. 25 Cab Door Sensor......................................................................... 25 Raising................................................................................. 26 Lowering................................................................................ 27 TRANSPORTING THE LOADER ON A TRAILER........................................................ 29 Loading And Unloading................................................................... 29 Fastening............................................................................... 29 TOWING THE LOADER........................................................................... 31 Procedure............................................................................... 31 REMOTE START TOOL KIT - MEL1563............................................................. 33 Remote Start Tool - MEL1563............................................................. 33 Service Tool Harness Communicator - MEL1566............................................. 35 Remote Start Procedure.................................................................. 35 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666.............................................. 39 Description............................................................................. 39 Remote Start Tool (Service Tool) - 7022042.............................................. 40 Loader Service Tool Harness - 6689747................................................... 41 Computer Service Tool Harness - 6689746................................................. 42 Remote Start Procedure.................................................................. 43 SERVICE SCHEDULE............................................................................ 47 Maintenance Intervals................................................................... 47 ENGINE AIR CLEANER.......................................................................... 49 Replacing Filters....................................................................... 49 ENGINE COOLING SYSTEM....................................................................... 51 Cleaning................................................................................ 51 Checking And Adding Coolant............................................................. 54 Removing and Replacing Coolant.......................................................... 55 FUEL SYSTEM................................................................................. 57 Fuel Specifications..................................................................... 57 Biodiesel Blend Fuel.................................................................... 57 Filling The Fuel Tank................................................................... 58 Removing Water From Main Fuel Filter.................................................... 59 Replacing Fuel Pre-Filter............................................................... 60 Replacing Main Fuel Filter.............................................................. 61 ENGINE LUBRICATION SYSTEM................................................................... 63 Checking And Adding Engine Oil.......................................................... 63 Engine Oil Chart........................................................................ 63 Removing And Replacing Oil And Filter................................................... 64 HYDRAULIC / HYDROSTATIC SYSTEM.............................................................. 67 Checking And Adding Fluid............................................................... 67 Hydraulic / Hydrostatic Fluid Chart..................................................... 67 Removing And Replacing Hydraulic Fluid.................................................. 68 Removing And Replacing Hydraulic / Hydrostatic Filter................................... 70 Removing And Replacing Hydraulic Charge Filter.......................................... 71 Replacing Reservoir Breather Cap........................................................ 72 BOB-TACH (HAND LEVER)....................................................................... 73 Inspection And Maintenance.............................................................. 73 BOB-TACH (POWER)............................................................................ 75 Inspection And Maintenance.............................................................. 75 LUBRICATING THE LOADER...................................................................... 77 Lubrication Locations................................................................... 77 PIVOT PINS.................................................................................. 81 Inspection And Maintenance.............................................................. 81 LOADER STORAGE AND RETURN TO SERVICE........................................................ 83 Storage................................................................................. 83 Return To Service....................................................................... 83 STOPPING THE ENGINE AND LEAVING THE LOADER.................................................. 85 Procedure............................................................................... 85 EMERGENCY EXIT.............................................................................. 87 Rear Window Identification.............................................................. 87 Rear Window Removal (Latches)........................................................... 87 Rear Window Removal (Rubber Cord)....................................................... 88 External Access (Rear Window With Latches).............................................. 88 External Access (Rear Window With Rubber Cord).......................................... 89 Front Door.............................................................................. 90 SEAT BELT................................................................................... 93 Inspection And Maintenance.............................................................. 93 HYDRAULIC SYSTEM................................................................................ 95 HYDRAULIC / HYDROSTATIC SCHEMATICS.......................................................... 99 HYDRAULIC SYSTEM INFORMATION................................................................107 Glossary Of Hydraulic / Hydrostatic Symbols.............................................107 Troubleshooting.........................................................................111 CYLINDER (LIFT).............................................................................113 Testing.................................................................................113 Removal And Installation................................................................114 Parts Identification....................................................................116 Disassembly.............................................................................117 Assembly................................................................................119 CYLINDER (TILT).............................................................................123 Testing.................................................................................123 Removal And Installation................................................................124 Base End Pivot Pin Removal And Installation.............................................125 Parts Identification....................................................................126 Disassembly.............................................................................127 Assembly................................................................................129 CYLINDER (BOB-TACH).........................................................................133 Testing.................................................................................133 Removal And Installation................................................................134 Parts Identification....................................................................135 Disassembly.............................................................................136 Assembly................................................................................137 MAIN RELIEF VALVE...........................................................................141 Description.............................................................................141 Testing.................................................................................142 Adjusting...............................................................................144 Removal And Installation................................................................145 HYDRAULIC CONTROL VALVE (STANDARD)..........................................................147 Description.............................................................................147 Removal And Installation................................................................148 Mount Bracket Removal And Installation..................................................151 Identification Chart....................................................................152 Lift Load Check Valve Removal And Installation..........................................153 Load Check Valve Removal And Installation (Tilt And Auxiliary)..........................154 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................155 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........155 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........156 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............156 Port Relief Valve Removal And Installation..............................................157 Plug Removal And Installation...........................................................159 Rubber Boot Removal And Installation....................................................160 End Cap Block Removal And Installation..................................................160 Lift Spool And Detent Removal And Installation..........................................161 Tilt Spool Removal And Installation.....................................................169 Auxiliary Spool Removal And Installation................................................171 Auxiliary Solenoid Removal And Installation.............................................172 Solenoid Removal And Installation.......................................................173 Lock Valve Removal And Installation.....................................................174 Lift Arm Bypass Orifice Removal And Installation........................................176 Main Relief Valve Removal And Installation..............................................176 Check Valve Removal And Installation....................................................177 HYDRAULIC CONTROL VALVE (SJC)...............................................................179 Description.............................................................................179 Removal And Installation................................................................179 Actuator Removal And Installation (In Loader)...........................................182 Actuator Removal And Installation (Out Of Loader).......................................183 Identification Chart....................................................................186 Mount Bracket Removal And Installation..................................................187 Lift Load Check Valve Removal And Installation..........................................187 Load Check Valve Removal And Installation (Tilt And Auxiliary)..........................188 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................189 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........189 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........190 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............190 Port Relief Valve Removal And Installation..............................................191 Plug Removal And Installation...........................................................193 End Cap Block Removal And Installation..................................................194 Lift Spool Removal And Installation.....................................................194 Lift Spool Disassembly And Assembly.....................................................196 Tilt Spool Removal And Installation.....................................................197 Tilt Spool Disassembly And Assembly.....................................................198 Auxiliary Spool Removal And Installation................................................199 Auxiliary Solenoid Removal And Installation.............................................200 Solenoid Removal And Installation.......................................................201 Lock Valve Removal And Installation.....................................................202 Lift Arm Bypass Orifice Removal And Installation........................................204 Main Relief Valve Removal And Installation..............................................204 Check Valve Removal And Installation....................................................205 LIFT ARM BYPASS CONTROL VALVE...............................................................207 Description.............................................................................207 Testing.................................................................................207 Removal And Installation................................................................208 Bracket Removal And Installation........................................................209 Disassembly And Assembly................................................................209 HYDRAULIC PUMP..............................................................................211 Description.............................................................................211 Pump Test At Quick Couplers.............................................................212 Direct Pump Test (Standard Section).....................................................215 Direct Pump Test (Charge Section).......................................................217 Removal And Installation................................................................219 Hydraulic Pump Startup..................................................................221 Parts Identification....................................................................222 Disassembly And Assembly................................................................223 HYDRAULIC / HYDROSTATIC FILTERS.............................................................225 Description.............................................................................225 Housing Removal And Installation........................................................225 HYDRAULIC FLUID RESERVOIR...................................................................227 Description.............................................................................227 Removal And Installation................................................................227 Hydraulic Fluid Screen..................................................................228 Gauge Removal And Installation..........................................................228 OIL COOLER..................................................................................229 Removal And Installation................................................................229 BUCKET POSITION VALVE.......................................................................231 Description.............................................................................231 Solenoid Removal And Installation.......................................................231 Solenoid Testing........................................................................232 Removal And Installation................................................................233 Disassembly And Assembly................................................................235 REAR AUXILIARY DIVERTER VALVE...............................................................237 Description.............................................................................237 Solenoid Testing........................................................................237 Removal And Installation................................................................238 Disassembly And Assembly................................................................239 BOB-TACH (POWER) BLOCK......................................................................245 Description.............................................................................245 Testing Relief Valve....................................................................245 Removal And Installation................................................................247 Disassembly And Assembly................................................................249 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.....................................................255 Description.............................................................................255 Removal And Installation................................................................255 Disassembly And Assembly................................................................256 HYDROSTATIC SYSTEM..............................................................................259 HYDROSTATIC SYSTEM INFORMATION..............................................................261 Description.............................................................................261 Troubleshooting.........................................................................262 HYDROSTATIC DRIVE MOTOR.....................................................................263 Description.............................................................................263 Removing And Replacing Fluid............................................................264 Removal And Installation................................................................264 Parts Identification (MCR5T)............................................................266 Parts Identification (MCR6T) (Two-Speed)................................................267 Disassembly And Assembly................................................................268 CHARGE PRESSURE.............................................................................279 Description.............................................................................279 Testing.................................................................................279 Adjusting...............................................................................281 Sender Removal And Installation.........................................................283 HYDROSTATIC PUMP............................................................................285 Description.............................................................................285 Removal And Installation................................................................286 Hydrostatic Pump Startup................................................................287 Replenishing / High Pressure Relief Valve Removal And Installation......................288 Parts Identification (Left Half)........................................................289 Parts Identification (Right Half).......................................................290 Disassembly.............................................................................291 Assembly................................................................................298 HYDROSTATIC PUMP (SJC)......................................................................305 Description.............................................................................305 Hydraulic Controller Removal And Installation...........................................306 Removal And Installation................................................................308 Hydrostatic Pump Startup................................................................309 Parts Identification....................................................................310 High Pressure Relief And Bypass Valve...................................................311 Charge Relief Valve.....................................................................312 Disassembly And Assembly................................................................313 Mechanical Neutral Adjustment...........................................................325 Hydraulic Controller Neutral Adjustment.................................................328 DRIVE BELT..................................................................................333 Belt Adjustment.........................................................................333 Belt Replacement........................................................................333 Tensioner Pulley Removal And Installation...............................................334 Tensioner Pulley Disassembly And Assembly...............................................334 TWO-SPEED / BRAKE VALVE.....................................................................335 Description.............................................................................335 Valve Block Removal And Installation....................................................336 Valve Block Disassembly And Assembly....................................................338 DRAIN MANIFOLD..............................................................................341 Description.............................................................................341 Drain Manifold Removal And Installation.................................................342 DRIVE SYSTEM....................................................................................343 BRAKE.......................................................................................345 Description.............................................................................345 Block Removal And Installation..........................................................345 Block Disassembly And Assembly..........................................................347 TRACK UNDERCARRIAGE COMPONENTS..............................................................349 Description.............................................................................349 Checking Tension........................................................................350 Adjusting...............................................................................351 Track Removal And Installation..........................................................353 Idler (Front) Removal And Installation..................................................355 Track Tensioner Disassembly And Assembly................................................357 Idler (Rear) Removal And Installation...................................................359 Roller Removal And Installation.........................................................359 Sprocket Removal And Installation.......................................................360 TRACK MAINTENANCE...........................................................................361 Track Damage Identification.............................................................361 MAINFRAME.......................................................................................373 SEAT BAR....................................................................................377 Description.............................................................................377 Removal And Installation................................................................377 Disassembly And Assembly................................................................378 Compression Spring Disassembly And Assembly.............................................379 OPERATOR CAB................................................................................381 Gas Spring Removal And Installation.....................................................381 Gas Spring Bracket Disassembly And Assembly.............................................382 Removal And Installation................................................................382 OPERATOR SEAT (SUSPENSION)..................................................................385 Removal And Installation................................................................385 Slide Rail Removal And Installation.....................................................385 Seat Belt Removal And Installation......................................................386 Lower Cushion Removal...................................................................386 Lower Cushion Installation..............................................................387 Back Cushion Removal And Installation...................................................387 Shock Removal And Installation..........................................................388 3-Point Seat Belt Removal And Installation..............................................388 BOB-TACH (HAND LEVER).......................................................................391 Description.............................................................................391 Removal And Installation................................................................391 Lever And Wedge Disassembly And Assembly................................................393 Pivot Pin Bushing And Seal Removal And Installation.....................................394 BOB-TACH (POWER)............................................................................395 Description.............................................................................395 Removal And Installation................................................................395 Lever And Wedge Disassembly And Assembly................................................397 Pivot Pin Bushing And Seal Removal And Installation.....................................399 LIFT ARMS...................................................................................401 Removal And Installation................................................................401 REAR GRILLE.................................................................................405 Removal.................................................................................405 Installation............................................................................405 REAR DOOR (TAILGATE)........................................................................407 Removal And Installation................................................................407 Striker Removal And Installation........................................................408 Striker Disassembly And Assembly........................................................408 Striker (Adjusting).....................................................................409 Latch Removal And Installation..........................................................409 FUEL TANK...................................................................................411 Removal And Installation................................................................411 Fuel Fill Screen Removal And Installation...............................................412 Fuel Level Sender Removal And Installation..............................................412 CONTROL PEDALS AND LINKAGES.................................................................413 Description.............................................................................413 Pedal Removal And Installation..........................................................413 Linkage Removal And Installation........................................................414 Pedal (Adjusting).......................................................................415 Floor Pan Removal And Installation......................................................416 CONTROL PEDALS AND LINKAGES (SJC)...........................................................417 Description.............................................................................417 CONTROL PANEL...............................................................................419 Description.............................................................................419 Removal And Installation................................................................420 Disassembly And Assembly................................................................422 Linkage Removal And Installation........................................................424 Pintle Arm Disassembly And Assembly.....................................................427 Linkage Neutral (Adjusting).............................................................428 Linkage Travel (Adjusting)..............................................................431 Shock Removal And Installation..........................................................435 CONTROL PANEL (SJC).........................................................................437 Description.............................................................................437 Removal And Installation................................................................438 CONTROL HANDLE / LEVER......................................................................439 Description.............................................................................439 Lever Removal And Installation..........................................................439 Boot Removal And Installation...........................................................440 CONTROL HANDLE / LEVER (SJC)................................................................441 Description.............................................................................441 Joystick Testing........................................................................441 Joystick Removal And Installation.......................................................442 WINDOW (REAR)...............................................................................443 Rear Window Identification..............................................................443 Removal (Rubber Cord)...................................................................443 Installation (Rubber Cord)..............................................................444 Removal And Installation (Latches)......................................................446 Disassembly And Assembly (Latches)......................................................446 WINDOW (TOP)................................................................................447 Removal And Installation................................................................447 WINDOW (SIDE)...............................................................................449 Removal And Installation................................................................449 CAB DOOR....................................................................................451 Description.............................................................................451 Removal And Installation................................................................451 Disassembly And Assembly................................................................452 Aligning................................................................................453 Adjusting...............................................................................454 Checking Operation......................................................................454 ARMREST.....................................................................................455 Description.............................................................................455 Removal And Installation................................................................456 Disassembly And Assembly................................................................457 LEFT SIDE LOWER PANEL.......................................................................459 Removal And Installation................................................................459 Disassembly And Assembly................................................................461 RIGHT SIDE LOWER PANEL......................................................................463 Removal And Installation................................................................463 Disassembly And Assembly................................................................464 HEADLINER...................................................................................467 Removal And Installation................................................................467 REAR FAN DUCT PANEL.........................................................................469 Removal And Installation................................................................469 ELECTRICAL SYSTEM AND ANALYSIS..................................................................471 ELECTRICAL SCHEMATICS.......................................................................475 ELECTRICAL SYSTEM INFORMATION...............................................................516 Glossary Of Electrical Symbols..........................................................516 Deluxe Cab Harness Connectors...........................................................519 Mainframe / Engine Start Harness Connectors - Manual Controls...........................520 Mainframe / Engine Start Harness Connectors - SJC Controls..............................521 Engine Sensor Harness Connectors........................................................522 Description.............................................................................523 Fuse And Relay Location / Identification................................................523 Troubleshooting.........................................................................526 Solenoid Testing........................................................................527 BATTERY.....................................................................................528 Battery Maintenance.....................................................................528 Maintaining Battery Charge Level........................................................528 Battery Service During Machine Storage..................................................528 Battery Testing.........................................................................529 Battery Charging........................................................................529 Using A Booster Battery (Jump Starting).................................................530 Removal And Installation................................................................531 Removal And Installation................................................................532 ALTERNATOR..................................................................................534 Belt Adjustment.........................................................................534 Belt Replacement........................................................................534 Charging System Inspection..............................................................535 Alternator Voltage Testing..............................................................536 Low Voltage Testing.....................................................................536 High Voltage Testing....................................................................537 Removal And Installation................................................................537 Parts Identification....................................................................539 STARTER.....................................................................................540 Testing.................................................................................540 Removal And Installation................................................................540 Parts Identification....................................................................541 INSTRUMENT PANELS...........................................................................542 Left Panel..............................................................................542 Display Screen..........................................................................544 Right Panel.............................................................................545 Left Switch Panel.......................................................................547 Right Switch Panel......................................................................547 Left Side Lower Panel...................................................................548 Right Side Lower Panel..................................................................548 Radio...................................................................................549 Rear View Camera System.................................................................551 Left Panel Removal And Installation.....................................................553 Right Panel Removal And Installation....................................................553 Alarm Disassembly And Assembly..........................................................554 Left Switch Panel Removal And Installation..............................................555 Right Switch Panel Removal And Installation.............................................555 LIGHTS......................................................................................556 Front Removal And Installation..........................................................556 Rear Removal And Installation...........................................................557 Cab Light Removal And Installation......................................................557 BOBCAT CONTROLLERS (ACS AND AUXILIARY)......................................................558 Description.............................................................................558 Connector And Wire Identification.......................................................559 Removal And Installation................................................................563 BOBCAT CONTROLLER (GATEWAY).................................................................564 Description.............................................................................564 Connector Identification................................................................565 Removal And Installation................................................................568 BOBCAT CONTROLLER (SJC) (DRIVE).............................................................570 Description.............................................................................570 Connector Identification................................................................571 Removal And Installation................................................................574 ENGINE CONTROL UNIT (ECU)...................................................................576 Description.............................................................................576 Cleaning................................................................................577 Removal And Installation................................................................578 DIAGNOSTIC SERVICE CODES....................................................................580 Viewing Service Codes...................................................................580 Service Codes List......................................................................581 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™).....................................................596 Description.............................................................................596 Inspecting The BICS™ (Engine STOPPED - Key ON)..........................................597 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)....597 Inspecting The Seat Bar Sensor (Engine RUNNING).........................................597 Inspecting The Traction Lock And Parking Brake (Engine RUNNING).........................597 Inspecting The Lift Arm Bypass Control..................................................597 Inspecting Deactivation Of Lift And Tilt Functions (SJC)................................597 Troubleshooting.........................................................................598 SEAT BAR SENSOR.............................................................................600 Description.............................................................................600 Troubleshooting.........................................................................600 Testing.................................................................................601 Removal.................................................................................602 Installation............................................................................604 Bobcat Interlock Control System (BICS™) Circuit Test....................................605 TRACTION LOCK...............................................................................608 Description.............................................................................608 Troubleshooting.........................................................................609 Inspecting..............................................................................610 ELECTRICAL / HYDRAULIC CONTROLS.............................................................612 Identification Chart....................................................................612 Description.............................................................................613 Identification Chart ACD Group 0........................................................614 Identification Chart ACD Group 1........................................................615 Identification Chart ACD Group 2........................................................616 Identification Chart ACD Group 3........................................................617 ELECTRICAL / HYDRAULIC CONTROLS (SJC).......................................................618 Identification Chart....................................................................618 Description.............................................................................619 Identification Chart ACD Group 0........................................................620 Identification Chart ACD Group 1........................................................621 Identification Chart ACD Group 2........................................................622 Identification Chart ACD Group 3........................................................623 SERVICE PC (LAPTOP COMPUTER)................................................................624 Connecting Remote Start Tool............................................................624 Connecting Remote Start Tool (Service Tool).............................................624 CALIBRATION.................................................................................626 Description.............................................................................626 Actuator Testing........................................................................626 Lift And Tilt Calibration (SJC).........................................................629 Hydrostatic Pump Calibration (SJC)......................................................631 STEERING DRIFT COMPENSATION (OPERATOR MODE).................................................636 Description.............................................................................636 Operation...............................................................................636 STEERING DRIFT COMPENSATION (SERVICE MODE)..................................................638 Description.............................................................................638 Operation...............................................................................638 CONTROL PANEL SETUP.........................................................................640 Right Panel Setup (Deluxe Instrumentation Panel)........................................640 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...............................................644 Password Description....................................................................644 Changing The Owner Password.............................................................644 Changing The User Passwords.............................................................645 Password Lockout Feature................................................................645 MAINTENANCE CLOCK...........................................................................646 Description.............................................................................646 Setup...................................................................................647 Reset...................................................................................650 BACK-UP ALARM SYSTEM........................................................................652 Description.............................................................................652 Inspecting..............................................................................652 Adjusting Switch Position...............................................................653 Troubleshooting (Standard)..............................................................654 Alarm Removal And Installation..........................................................655 Switch Removal And Installation.........................................................655 FRONT HORN..................................................................................656 Removal And Installation................................................................656 Troubleshooting.........................................................................657 ENGINE SPEED CONTROL (HAND).................................................................658 Removal And Installation................................................................658 ENGINE SPEED CONTROL (FOOT).................................................................660 Removal And Installation................................................................660 Disassembly and Assembly................................................................661 Pedal (Adjusting).......................................................................663 Floor Pan Removal And Installation......................................................663 CAMSHAFT AND CRANKSHAFT POSITION SENSOR.....................................................664 Removal And Installation................................................................664 BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS...................................................666 Description.............................................................................666 Removal And Installation................................................................666 Procedure...............................................................................667 ENGINE SERVICE..................................................................................668 ENGINE INFORMATION..........................................................................672 Description.............................................................................672 Specifications..........................................................................673 Sensor Location.........................................................................675 Torque Values...........................................................................679 Troubleshooting.........................................................................681 Engine Removal And Installation.........................................................683 Engine Mount Replacement................................................................693 Compression - Testing...................................................................695 Injector Signal - Testing...............................................................697 DIESEL PARTICULATE FILTER (DPF) SYSTEM......................................................700 Description.............................................................................700 DPF Icons...............................................................................700 DPF Regeneration Tables.................................................................701 Automatic Regeneration Operation........................................................702 Forced Regeneration Operation...........................................................703 Forced Parked Regeneration Operation....................................................704 Inhibit Mode Operation..................................................................705 Service Regeneration....................................................................706 Removal And Installation................................................................707 DPF Cleaning............................................................................708 AIR CLEANER.................................................................................710 Housing Removal And Installation........................................................710 ENGINE COOLING SYSTEM.......................................................................712 Radiator / Oil Cooler Removal And Installation..........................................712 Hydraulic Fan Description...............................................................715 Fan Duct Removal And Installation.......................................................715 Hydraulic Fan Motor Assembly Removal And Installation...................................716 Fan Removal And Installation............................................................717 Hydraulic Fan Motor Removal And Installation............................................718 Hydraulic Fan Motor Disassembly And Assembly............................................719 Fan Shroud Removal And Installation.....................................................725 Water Pump Removal And Installation.....................................................725 Thermostat Housing Removal And Installation.............................................726 Testing The Thermostat..................................................................728 LUBRICATION SYSTEM..........................................................................730 Description.............................................................................730 Oil Pan Removal And Installation........................................................731 Oil Pump Removal And Installation.......................................................732 Oil Pump Relief Valve Description.......................................................732 Oil Cooler Removal And Installation.....................................................732 Oil Cooler Bypass description...........................................................733 Oil Filter Head Removal And Installation................................................733 FUEL SYSTEM.................................................................................734 Description.............................................................................734 Fuel Filter Housing Removal And Installation............................................735 Fuel Recirculation Valve (FRV) Removal And Installation.................................735 Fuel Temperature Sensor Removal And Installation........................................735 Fuel Pre-Filter Removal And Installation................................................736 Fuel Lift Pump Removal And Installation.................................................737 Fuel Cooler Removal And Installation....................................................738 Transfer Pump / High Pressure Pump Removal And Installation.............................738 Fuel Injector Removal And Installation..................................................741 Injector Coding.........................................................................743 CYLINDER HEAD...............................................................................744 Glow Plugs Testing......................................................................744 Glow Plug Removal And Installation......................................................745 Cylinder Head Removal And Installation..................................................746 Cylinder Head Disassembly And Assembly..................................................751 Cylinder Head Inspection................................................................752 Cylinder Head Top Clearance.............................................................753 Valve Step Height.......................................................................754 Valve Stem Height.......................................................................754 Valve Guide.............................................................................755 Valve...................................................................................755 Valve Spring............................................................................756 Rocker Arm Shaft Disassembly And Assembly...............................................757 Rocker Arm Shaft Inspection.............................................................758 Push Rod Inspection.....................................................................758 CRANKSHAFT AND PISTONS......................................................................760 Piston And Connecting Rod Removal And Installation......................................760 Piston And Connecting Rod Inspection....................................................761 Crankshaft Removal And Installation.....................................................763 Cylinder Block Inspection...............................................................766 Crankshaft Inspection...................................................................768 Connecting Rod Inspection...............................................................768 Engine Component Class..................................................................769 CAMSHAFT....................................................................................772 Removal And Installation................................................................772 Inspecting..............................................................................773 GEARCASE....................................................................................776 Gearcase Cover Removal And Installation.................................................776 Gear Backlash...........................................................................777 Gear Timing.............................................................................778 Idle Gear Removal And Installation......................................................779 Idle Gear Inspection....................................................................779 TURBOCHARGER................................................................................780 Description.............................................................................780 Removal And Installation................................................................781 Inspection..............................................................................784 FLYWHEEL AND HOUSING........................................................................786 Flywheel Removal And Installation.......................................................786 Ring Gear Removal And Installation......................................................787 Housing Removal And Installation........................................................787 EXHAUST GAS RECIRCULATION (EGR) SYSTEM......................................................788 Description.............................................................................788 Removal And Installation................................................................789 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)................................................792 AIR CONDITIONING SYSTEM FLOW................................................................794 Description.............................................................................794 A/C System Diagram......................................................................795 Components..............................................................................796 Safety Equipment........................................................................799 REGULAR MAINTENANCE.........................................................................800 Filters.................................................................................800 Belt Adjustment.........................................................................801 Belt Replacement........................................................................801 Air Conditioning Condenser..............................................................802 Air Conditioning Lubrication............................................................802 Air Conditioning Service Chart..........................................................803 Evaporator / Heater Coil................................................................804 TROUBLESHOOTING.............................................................................806 Blower Motor Does Not Operate...........................................................806 Blower Motor Operates Normally, But Air Flow Is Insufficient............................806 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............806 The Compressor Does Not Operate At All, Or Operates Improperly..........................806 The Compressor Does Not Operate At All, Or Operates Improperly (Cont’d).................807 Gauge Pressure Related Troubleshooting..................................................807 Troubleshooting Tree....................................................................809 Temperature / Pressure Chart............................................................813 Poor A/C Performance....................................................................814 HVAC Repair And Leaks...................................................................815 Electrical System.......................................................................816 Engine Coolant Bypassing The Heater Valve...............................................822 Heater Valve Not Opening Or Closing.....................................................823 SYSTEM CHARGING AND RECLAMATION.............................................................824 Refrigerant Identification..............................................................824 Reclamation And Charging With Recovery / Charging Unit..................................825 COMPRESSOR..................................................................................828 Removal And Installation................................................................828 Oil.....................................................................................829 Oil Check...............................................................................830 CONDENSER...................................................................................832 Removal And Installation................................................................832 RECEIVER / DRIER............................................................................834 Receiver / Drier Removal And Installation...............................................834 Pressure Switch Removal And Installation................................................835 Schrader® Valve Removal And Installation................................................836 EVAPORATOR / HEATER UNIT....................................................................838 Removal And Installation................................................................838 EXPANSION VALVE.............................................................................840 Removal And Installation................................................................840 EVAPORATOR COIL.............................................................................842 Removal And Installation................................................................842 HEATER COIL.................................................................................844 Removal And Installation................................................................844 BLOWER FAN..................................................................................846 Removal And Installation................................................................846 Disassembly And Assembly................................................................846 HEATER VALVE................................................................................850 Removal And Installation................................................................850 EVAPORATOR / HEATER COVER...................................................................852 Removing................................................................................852 Installing..............................................................................852 SPECIFICATIONS..................................................................................854 LOADER SPECIFICATIONS.......................................................................856 Machine Dimensions......................................................................856 Performance.............................................................................857 Engine..................................................................................857 Drive System............................................................................858 Controls................................................................................858 Hydraulic System........................................................................859 Electrical System.......................................................................860 Capacities..............................................................................860 Tracks..................................................................................861 Ground Pressure.........................................................................861 Environmental...........................................................................861 Temperature Range.......................................................................861 TECHNICAL SERVICE GUIDE SPECIFICATIONS......................................................862 Engine..................................................................................862 Engine Torques..........................................................................862 Cooling System..........................................................................862 Loader Torques..........................................................................863 Hydraulic / Hydrostatic System..........................................................863 Fuel Consumption........................................................................863 TORQUE SPECIFICATIONS FOR BOLTS.............................................................864 Torque For General SAE Bolts............................................................864 Torque For General Metric Bolts.........................................................865 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................866 Straight Thread O-ring Fitting..........................................................866 Flare Fitting...........................................................................867 Tubelines And Hoses.....................................................................867 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................868 Specifications..........................................................................868 CONVERSIONS.................................................................................870 Decimal And Millimeter Equivalent Chart.................................................870 U.S. To Metric Conversion Chart.........................................................870 SERVICE TOOLS REQUIRED......................................................................872 Remote Start Tools......................................................................872 Hydraulic Tools.........................................................................873 Mainframe And Drive Tools...............................................................876 Electrical Tools........................................................................879 Engine Tools............................................................................880 HVAC Tools..............................................................................885 ALPHABETICAL INDEX..............................................................................886
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