Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Bobcat T450 Skid-Steer Loader Service Manual 6990394 – PDF DOWNLOAD
$35.95
Bobcat T450 Skid-Steer Loader Service Manual 6990394 – PDF DOWNLOAD
S/N AUVP11001 & Above
S/N B1EM11001 & Above
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Bobcat T450 Skid-Steer Loader Service Manual 6990394 – PDF DOWNLOAD
FILE DETAILS:
Bobcat T450 Skid-Steer Loader Service Manual 6990394 – PDF DOWNLOAD
Language : English
Pages : 1068
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T450 Skid-Steer Loader Service Manual 6990394 – PDF DOWNLOAD
S/N AUVP11001 & Above
S/N B1EM11001 & Above
FOREWORD:
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS / FOPS (Including side screens) is in good condition and is not modified.
2. Check that ROPS mounting hardware is tightened and is Bobcat approved.
3. The seat belt must be correctly installed, functional and in good condition.
4. The seat bar must be correctly adjusted, clean and lubricated.
5. Check lift arm support device, replace if damaged.
6. Machine signs (decals) must be legible and in the correct location.
7. Steering levers, hand controls and foot pedals must return to neutral (as applicable).
8. Check for correct function of the work lights.
9. The parking brake must function correctly.
10. Enclosure door latches must open and close freely.
11. Bob-Tach® 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 Skid-Steer Loader Service Manual 6990394 – PDF DOWNLOAD
MAINTENANCE SAFETY.............................................................................. 3 CONTENTS........................................................................................ 5 FOREWORD........................................................................................ 7 FOREWORD.................................................................................... 9 SAFETY INSTRUCTIONS......................................................................... 11 FIRE PREVENTION............................................................................. 13 Maintenance............................................................................. 13 Operation............................................................................... 13 Electrical.............................................................................. 13 Hydraulic System........................................................................ 13 Fueling................................................................................. 13 Starting................................................................................ 13 Spark Arrester Exhaust System........................................................... 13 Welding And Grinding.................................................................... 14 Fire Extinguishers...................................................................... 14 SERIAL NUMBER LOCATIONS..................................................................... 15 Loader Serial Number.................................................................... 15 Engine Serial Number.................................................................... 15 DELIVERY REPORT............................................................................. 16 LOADER IDENTIFICATION....................................................................... 17 SAFETY AND MAINTENANCE.......................................................................... 19 LIFTING AND BLOCKING THE LOADER............................................................. 21 Procedure............................................................................... 21 LIFT ARM SUPPORT DEVICE..................................................................... 23 Description............................................................................. 23 Installing.............................................................................. 24 Removing................................................................................ 25 OPERATOR CAB................................................................................ 27 Description............................................................................. 27 Cab Door Sensor......................................................................... 27 Raising................................................................................. 28 Lowering................................................................................ 29 TRANSPORTING THE LOADER ON A TRAILER........................................................ 31 Loading And Unloading................................................................... 31 Fastening............................................................................... 31 TOWING THE LOADER........................................................................... 33 Procedure............................................................................... 33 REMOTE START TOOL KIT - MEL1563............................................................. 35 Remote Start Tool - MEL1563............................................................. 35 Service Tool Harness Communicator - MEL1566............................................. 37 Remote Start Procedure.................................................................. 37 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666.............................................. 41 Description............................................................................. 41 Remote Start Tool (Service Tool) - 7022042.............................................. 42 Loader Service Tool Harness - 6689747................................................... 43 Computer Service Tool Harness - 6689746................................................. 44 Remote Start Procedure.................................................................. 45 SERVICE SCHEDULE............................................................................ 49 Maintenance Intervals................................................................... 49 ENGINE AIR CLEANER.......................................................................... 51 Replacing Filters....................................................................... 51 ENGINE COOLING SYSTEM....................................................................... 53 Maintenance Platform.................................................................... 53 Cleaning................................................................................ 53 Checking And Adding Coolant............................................................. 56 Removing And Replacing Coolant.......................................................... 57 FUEL SYSTEM................................................................................. 59 Fuel Specifications..................................................................... 59 Biodiesel Blend Fuel.................................................................... 59 Filling The Fuel Tank................................................................... 60 Fuel Filter............................................................................. 61 Removing Air From The Fuel System....................................................... 62 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................................... 71 Removing And Replacing Hydraulic Charge Filter.......................................... 72 Replacing Reservoir Breather Cap........................................................ 75 BOB-TACH (HAND LEVER)....................................................................... 77 Inspection And Maintenance.............................................................. 77 BOB-TACH (POWER)............................................................................ 79 Inspection And Maintenance.............................................................. 79 LUBRICATING THE LOADER...................................................................... 81 Lubrication Locations................................................................... 81 PIVOT PINS.................................................................................. 85 Inspection And Maintenance.............................................................. 85 LOADER STORAGE AND RETURN TO SERVICE........................................................ 87 Storage................................................................................. 87 Return To Service....................................................................... 87 STOPPING THE ENGINE AND LEAVING THE LOADER.................................................. 89 Procedure............................................................................... 89 EMERGENCY EXIT.............................................................................. 91 Rear Window Identification.............................................................. 91 Rear Window Removal (Latches)........................................................... 91 Rear Window Removal (Rubber Cord)....................................................... 92 External Access (Rear Window With Latches).............................................. 92 External Access (Rear Window With Rubber Cord).......................................... 93 Front Door.............................................................................. 93 SEAT BELT................................................................................... 95 Inspection And Maintenance.............................................................. 95 HYDRAULIC SYSTEM................................................................................ 97 HYDRAULIC / HYDROSTATIC SCHEMATICS.......................................................... 101 HYDRAULIC SYSTEM INFORMATION................................................................ 117 Glossary Of Hydraulic / Hydrostatic Symbols............................................. 117 Troubleshooting......................................................................... 121 CYLINDER (LIFT)............................................................................. 123 Testing................................................................................. 123 Removal And Installation................................................................ 124 Parts Identification.................................................................... 126 Disassembly............................................................................. 127 Assembly................................................................................ 129 CYLINDER (TILT)............................................................................. 133 Testing................................................................................. 133 Removal And Installation................................................................ 134 Base End Pivot Pin Removal And Installation............................................. 135 Parts Identification.................................................................... 136 Disassembly............................................................................. 137 Assembly................................................................................ 139 CYLINDER (LIFT) (B1EM11240 & ABOVE)......................................................... 143 Testing................................................................................. 143 Removal And Installation................................................................ 144 Parts Identification.................................................................... 146 Disassembly............................................................................. 147 Assembly................................................................................ 149 CYLINDER (TILT) (B1EM11240 & ABOVE)......................................................... 153 Testing................................................................................. 153 Removal And Installation................................................................ 154 Base End Pivot Pin Removal And Installation............................................. 155 Parts Identification.................................................................... 156 Disassembly............................................................................. 157 Assembly................................................................................ 159 CYLINDER (BOB-TACH)......................................................................... 163 Testing................................................................................. 163 Removal And Installation................................................................ 164 Parts Identification.................................................................... 165 Disassembly............................................................................. 166 Assembly................................................................................ 167 MAIN RELIEF VALVE........................................................................... 171 Description............................................................................. 171 Testing................................................................................. 172 Adjusting............................................................................... 174 Removal And Installation................................................................ 175 HYDRAULIC CONTROL VALVE (STANDARD).......................................................... 177 Description............................................................................. 177 Removal And Installation................................................................ 178 Mount Bracket Removal And Installation.................................................. 181 Identification Chart.................................................................... 182 Lift Load Check Valve Removal And Installation.......................................... 183 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................... 184 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................... 185 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........... 185 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........... 186 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............ 186 Port Relief Valve Removal And Installation.............................................. 187 Plug Removal And Installation........................................................... 189 Rubber Boot Removal And Installation.................................................... 190 End Cap Block Removal And Installation.................................................. 190 Lift Spool And Detent Removal And Installation.......................................... 191 Tilt Spool Removal And Installation..................................................... 199 Auxiliary Spool Removal And Installation................................................ 201 Auxiliary Solenoid Removal And Installation............................................. 202 Solenoid Removal And Installation....................................................... 203 Lock Valve Removal And Installation..................................................... 204 Lift Arm Bypass Orifice Removal And Installation........................................ 206 Main Relief Valve Removal And Installation.............................................. 206 Check Valve Removal And Installation.................................................... 207 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)...................................................... 209 Description............................................................................. 209 Removal And Installation................................................................ 209 Actuator Removal And Installation (In Loader)........................................... 212 Actuator Removal And Installation (Out Of Loader)....................................... 213 Identification Chart.................................................................... 216 Mount Bracket Removal And Installation.................................................. 217 Lift Load Check Valve Removal And Installation.......................................... 217 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................... 218 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................... 219 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........... 219 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........... 220 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............ 220 Port Relief Valve Removal And Installation.............................................. 221 Plug Removal And Installation........................................................... 223 End Cap Block Removal And Installation.................................................. 224 Lift Spool Removal And Installation..................................................... 224 Lift Spool Disassembly And Assembly..................................................... 226 Tilt Spool Removal And Installation..................................................... 227 Tilt Spool Disassembly And Assembly..................................................... 228 Auxiliary Spool Removal And Installation................................................ 229 Auxiliary Solenoid Removal And Installation............................................. 230 Solenoid Removal And Installation....................................................... 231 Lock Valve Removal And Installation..................................................... 232 Lift Arm Bypass Orifice Removal And Installation........................................ 234 Main Relief Valve Removal And Installation.............................................. 234 Check Valve Removal And Installation.................................................... 235 LIFT ARM BYPASS CONTROL VALVE............................................................... 237 Description............................................................................. 237 Testing................................................................................. 237 Removal And Installation................................................................ 238 Bracket Removal And Installation........................................................ 239 Disassembly And Assembly................................................................ 239 HYDRAULIC PUMP.............................................................................. 241 Description............................................................................. 241 Pump Test At Quick Couplers............................................................. 242 Direct Pump Test (Standard Section)..................................................... 244 Direct Pump Test (Charge Section)....................................................... 246 Removal And Installation................................................................ 248 Hydraulic Pump Startup.................................................................. 250 Parts Identification.................................................................... 251 Disassembly And Assembly................................................................ 252 HYDRAULIC / HYDROSTATIC FILTERS............................................................. 253 Description............................................................................. 253 Housing Removal And Installation........................................................ 253 HYDRAULIC FLUID RESERVOIR................................................................... 255 Description............................................................................. 255 Removal And Installation................................................................ 255 Hydraulic Fluid Screen.................................................................. 256 Gauge Removal And Installation.......................................................... 256 OIL COOLER.................................................................................. 257 Removal And Installation................................................................ 257 BUCKET POSITION VALVE....................................................................... 259 Description............................................................................. 259 Solenoid Removal And Installation....................................................... 259 Solenoid Testing........................................................................ 260 Removal And Installation................................................................ 260 Disassembly And Assembly................................................................ 262 REAR AUXILIARY DIVERTER VALVE............................................................... 263 Description............................................................................. 263 Solenoid Testing........................................................................ 263 Removal And Installation................................................................ 264 Disassembly And Assembly................................................................ 265 BOB-TACH (POWER) BLOCK (EARLIER MODELS)..................................................... 271 Description............................................................................. 271 Removal And Installation................................................................ 271 Disassembly And Assembly................................................................ 273 BOB-TACH (POWER) BLOCK (LATER MODELS)....................................................... 281 Description............................................................................. 281 Testing Relief Valve.................................................................... 281 Removal And Installation................................................................ 283 Disassembly And Assembly................................................................ 285 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK..................................................... 291 Description............................................................................. 291 Removal And Installation................................................................ 292 Disassembly And Assembly (FFI/FI)....................................................... 293 Disassembly And Assembly (FFH/FH)....................................................... 295 HYDROSTATIC SYSTEM.............................................................................. 297 HYDROSTATIC SYSTEM INFORMATION.............................................................. 299 Description............................................................................. 299 Troubleshooting......................................................................... 300 HYDROSTATIC DRIVE MOTOR..................................................................... 301 Description............................................................................. 301 Removing And Replacing Fluid............................................................ 302 Removal And Installation................................................................ 302 Parts Identification (MCR5T)............................................................ 304 Parts Identification (MCR6T) (Two-Speed)................................................ 305 Disassembly And Assembly................................................................ 306 CHARGE PRESSURE............................................................................. 317 Description............................................................................. 317 Testing................................................................................. 317 Adjusting............................................................................... 319 Sender Removal And Installation......................................................... 321 HYDROSTATIC PUMP............................................................................ 323 Description............................................................................. 323 Removal And Installation................................................................ 324 Hydrostatic Pump Startup................................................................ 325 Replenishing / High Pressure Relief Valve Removal And Installation...................... 326 Parts Identification (Left Half)........................................................ 327 Parts Identification (Right Half)....................................................... 328 Disassembly............................................................................. 329 Assembly................................................................................ 336 HYDROSTATIC PUMP (SJC)...................................................................... 343 Description............................................................................. 343 Hydraulic Controller Removal And Installation........................................... 344 Removal And Installation................................................................ 346 Hydrostatic Pump Startup................................................................ 347 Parts Identification.................................................................... 348 High Pressure Relief And Bypass Valve................................................... 349 Charge Relief Valve..................................................................... 350 Disassembly And Assembly................................................................ 351 Mechanical Neutral Adjustment........................................................... 364 Hydraulic Controller Neutral Adjustment................................................. 366 DRIVE BELT.................................................................................. 371 Belt Adjustment......................................................................... 371 Belt Replacement........................................................................ 371 Tensioner Pulley Removal And Installation............................................... 372 Tensioner Pulley Disassembly And Assembly............................................... 372 TWO-SPEED / BRAKE VALVE..................................................................... 373 Description............................................................................. 373 Valve Block Removal And Installation.................................................... 374 Valve Block Disassembly And Assembly.................................................... 376 DRAIN MANIFOLD.............................................................................. 379 Description............................................................................. 379 Drain Manifold Removal And Installation................................................. 379 DRIVE SYSTEM.................................................................................... 381 BRAKE....................................................................................... 383 Description............................................................................. 383 Block Removal And Installation.......................................................... 383 Block Disassembly And Assembly.......................................................... 385 TRACK UNDERCARRIAGE COMPONENTS.............................................................. 387 Description............................................................................. 387 Checking Tension........................................................................ 388 Adjusting Tension (Earlier Models With Two Track Tension Fittings)...................... 389 Adjusting Tension (Later Models With One Track Tension Fitting)......................... 391 Track Removal And Installation.......................................................... 393 Idler (Front) Removal And Installation.................................................. 395 Track Tensioner Disassembly And Assembly................................................ 397 Idler (Rear) Removal And Installation................................................... 399 Roller Removal And Installation......................................................... 399 Sprocket Removal And Installation....................................................... 400 TRACK MAINTENANCE........................................................................... 401 Track Damage Identification............................................................. 401 MAINFRAME....................................................................................... 413 SEAT BAR.................................................................................... 417 Description............................................................................. 417 Removal And Installation................................................................ 417 Disassembly And Assembly................................................................ 418 Compression Spring Disassembly And Assembly............................................. 419 OPERATOR CAB................................................................................ 421 Gas Spring Removal And Installation..................................................... 421 Gas Spring Bracket Disassembly And Assembly............................................. 422 Removal And Installation................................................................ 422 OPERATOR SEAT (SUSPENSION).................................................................. 425 Removal And Installation................................................................ 425 Slide Rail Removal And Installation..................................................... 425 Seat Belt Removal And Installation...................................................... 426 Lower Cushion Removal................................................................... 426 Lower Cushion Installation.............................................................. 427 Back Cushion Removal And Installation................................................... 427 Shock Removal And Installation.......................................................... 428 3-Point Seat Belt Removal And Installation.............................................. 428 BOB-TACH (HAND LEVER)....................................................................... 431 Description............................................................................. 431 Removal And Installation................................................................ 431 Lever And Wedge Disassembly And Assembly................................................ 433 Pivot Pin Bushing And Seal Removal And Installation..................................... 435 BOB-TACH (POWER)............................................................................ 437 Description............................................................................. 437 Removal And Installation................................................................ 437 Lever And Wedge Disassembly And Assembly................................................ 439 Pivot Pin Bushing And Seal Removal And Installation..................................... 442 LIFT ARMS................................................................................... 443 Removal And Installation................................................................ 443 REAR GRILLE................................................................................. 447 Removal................................................................................. 447 Installation............................................................................ 447 REAR DOOR (TAILGATE)........................................................................ 449 Removal And Installation................................................................ 449 Striker Removal And Installation........................................................ 450 Striker Disassembly And Assembly........................................................ 450 Striker (Adjusting)..................................................................... 451 Latch Removal And Installation.......................................................... 451 FUEL TANK................................................................................... 453 Removal And Installation................................................................ 453 Fuel Level Sender Removal And Installation.............................................. 454 Fuel Fill Screen Removal And Installation............................................... 454 CONTROL PEDALS AND LINKAGES................................................................. 455 Description............................................................................. 455 Pedal Removal And Installation.......................................................... 455 Linkage Removal And Installation........................................................ 456 Pedal (Adjusting)....................................................................... 457 Floor Pan Removal And Installation...................................................... 458 CONTROL PEDALS AND LINKAGES (ACS)........................................................... 459 Description............................................................................. 459 Pedal Removal And Installation.......................................................... 459 Linkage Removal And Installation........................................................ 460 Pedal (Adjusting)....................................................................... 460 Floor Pan Removal And Installation...................................................... 461 CONTROL PEDALS AND LINKAGES (SJC)........................................................... 463 Description............................................................................. 463 CONTROL PANEL............................................................................... 465 Description............................................................................. 465 Removal And Installation................................................................ 466 Disassembly And Assembly................................................................ 468 Linkage Removal And Installation........................................................ 470 Pintle Arm Disassembly And Assembly..................................................... 473 Linkage Neutral (Adjusting)............................................................. 474 Linkage Travel (Adjusting).............................................................. 477 Shock Removal And Installation.......................................................... 481 CONTROL PANEL (SJC)......................................................................... 483 Description............................................................................. 483 Removal And Installation................................................................ 483 CONTROL HANDLE / LEVER...................................................................... 485 Description............................................................................. 485 Lever Removal And Installation.......................................................... 485 Boot Removal And Installation........................................................... 486 CONTROL HANDLE / LEVER (ACS)................................................................ 487 Description............................................................................. 487 Handle Sensor Removal And Installation.................................................. 487 Handle Removal And Installation......................................................... 490 Handle Disassembly And Assembly......................................................... 491 Lever Removal And Installation.......................................................... 491 Boot Removal And Installation........................................................... 492 CONTROL HANDLE / LEVER (SJC)................................................................ 493 Description............................................................................. 493 Joystick Testing........................................................................ 493 Joystick Removal And Installation....................................................... 494 WINDOW (REAR)............................................................................... 495 Rear Window Identification.............................................................. 495 Removal (Rubber Cord)................................................................... 495 Installation (Rubber Cord).............................................................. 496 Removal And Installation (Latches)...................................................... 498 Disassembly And Assembly (Latches)...................................................... 498 WINDOW (TOP)................................................................................ 499 Removal And Installation................................................................ 499 WINDOW (SIDE)............................................................................... 501 Removal And Installation................................................................ 501 CAB DOOR.................................................................................... 503 Description............................................................................. 503 Removal And Installation................................................................ 503 Disassembly And Assembly................................................................ 504 Aligning................................................................................ 505 Adjusting............................................................................... 506 Checking Operation...................................................................... 506 ARMREST..................................................................................... 507 Description............................................................................. 507 Removal And Installation................................................................ 508 Disassembly And Assembly................................................................ 509 LEFT SIDE LOWER PANEL....................................................................... 511 Removal And Installation................................................................ 511 Disassembly And Assembly................................................................ 513 RIGHT SIDE LOWER PANEL...................................................................... 515 Removal And Installation................................................................ 515 Disassembly And Assembly................................................................ 516 HEADLINER................................................................................... 519 Removal And Installation................................................................ 519 REAR FAN DUCT PANEL......................................................................... 521 Removal And Installation................................................................ 521 ELECTRICAL SYSTEM AND ANALYSIS.................................................................. 523 ELECTRICAL SCHEMATICS....................................................................... 529 ELECTRICAL SYSTEM INFORMATION............................................................... 675 Glossary Of Electrical Symbols.......................................................... 675 Standard Cab Harness Connectors......................................................... 678 Deluxe Cab Harness Connectors........................................................... 679 Mainframe / Engine Start Harness Connectors - Manual Controls........................... 680 Mainframe / Engine Start Harness Connectors - SJC / ACS Controls........................ 681 Engine Sensor Harness Connectors........................................................ 682 Description............................................................................. 683 Fuse And Relay Location / Identification................................................ 683 Troubleshooting......................................................................... 686 Solenoid Testing........................................................................ 687 BATTERY..................................................................................... 689 Servicing............................................................................... 689 Maintaining Battery Charge Level........................................................ 689 Battery Service During Machine Storage.................................................. 689 Battery Testing......................................................................... 690 Battery Charging........................................................................ 690 Using A Booster Battery (Jump Starting)................................................. 691 Removal And Installation................................................................ 692 ALTERNATOR.................................................................................. 697 Belt Adjustment......................................................................... 697 Belt Replacement........................................................................ 697 Charging System Inspection.............................................................. 698 Alternator Voltage Testing.............................................................. 699 Low Voltage Testing..................................................................... 699 High Voltage Testing.................................................................... 700 Removal And Installation................................................................ 700 Parts Identification.................................................................... 702 STARTER..................................................................................... 703 Testing................................................................................. 703 Removal And Installation................................................................ 703 Parts Identification.................................................................... 704 INSTRUMENT PANELS........................................................................... 705 Left Panel.............................................................................. 705 Display Screen.......................................................................... 707 Right Panel (Standard Key Panel)........................................................ 708 Right Panel (Keyless Start Panel)....................................................... 709 Right Panel (Deluxe Instrumentation Panel).............................................. 710 Left Switch Panel....................................................................... 712 Right Switch Panel...................................................................... 712 Left Side Lower Panel................................................................... 713 Right Side Lower Panel.................................................................. 713 Left Panel Removal And Installation..................................................... 714 Right Panel (Standard Key Panel) Removal And Installation............................... 714 Right Panel (Keyless Start Panel) Removal And Installation.............................. 715 Right Panel (Deluxe Instrumentation Panel) Removal And Installation..................... 715 Key Switch Disassembly And Assembly..................................................... 716 Alarm Disassembly And Assembly.......................................................... 716 Left Switch Panel Removal And Installation.............................................. 717 Right Switch Panel Removal And Installation............................................. 717 LIGHTS...................................................................................... 719 Front Removal And Installation.......................................................... 719 Rear Removal And Installation........................................................... 720 Cab Light Removal And Installation...................................................... 720 BOBCAT CONTROLLERS (ACS AND AUXILIARY)...................................................... 721 Description............................................................................. 721 Connector And Wire Identification....................................................... 722 Removal And Installation................................................................ 726 BOBCAT CONTROLLER (GATEWAY)................................................................. 727 Description............................................................................. 727 Connector Identification................................................................ 728 Removal And Installation................................................................ 731 BOBCAT CONTROLLER (SJC) (DRIVE)............................................................. 733 Description............................................................................. 733 Connector Identification................................................................ 734 Removal And Installation................................................................ 736 ENGINE CONTROL UNIT (ECU)................................................................... 737 Description............................................................................. 737 Cleaning................................................................................ 738 Removal And Installation................................................................ 739 DIAGNOSTIC SERVICE CODES.................................................................... 741 Viewing Service Codes................................................................... 741 Service Codes List...................................................................... 742 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..................................................... 751 Description............................................................................. 751 Inspecting The BICS™ (Engine STOPPED - Key ON).......................................... 752 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON).... 752 Inspecting The Seat Bar Sensor (Engine RUNNING)......................................... 752 Inspecting The Traction Lock And Parking Brake (Engine RUNNING)......................... 752 Inspecting The Lift Arm Bypass Control.................................................. 752 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)........................ 752 Troubleshooting......................................................................... 753 SEAT BAR SENSOR............................................................................. 755 Description............................................................................. 755 Troubleshooting......................................................................... 755 Testing................................................................................. 756 Removal................................................................................. 757 Installation............................................................................ 759 Bobcat Interlock Control System (BICS™) Circuit Test.................................... 760 TRACTION LOCK............................................................................... 763 Description............................................................................. 763 Troubleshooting......................................................................... 764 Inspecting.............................................................................. 765 CONTROL SYSTEM (ACS)........................................................................ 767 Description............................................................................. 767 Troubleshooting......................................................................... 768 Handle Sensor Connector Disassembly And Assembly........................................ 769 Switch Handle Removal................................................................... 770 Switch Handle Installation.............................................................. 772 Actuator Connector Disassembly And Assembly............................................. 775 Handle Lock Solenoid Removal And Installation........................................... 776 Handle Lock Solenoid Disassembly And Assembly........................................... 776 Foot Sensor Removal And Installation.................................................... 777 Foot Sensor Disassembly And Assembly.................................................... 778 Foot Sensor Lock Solenoid Removal And Installation...................................... 778 ELECTRICAL / HYDRAULIC CONTROLS............................................................. 779 Identification Chart.................................................................... 779 Description............................................................................. 780 Identification Chart ACD Group 0........................................................ 781 Identification Chart ACD Group 1........................................................ 782 Identification Chart ACD Group 2........................................................ 783 Identification Chart ACD Group 3........................................................ 784 ELECTRICAL / HYDRAULIC CONTROLS (ACS)....................................................... 785 Identification Chart.................................................................... 785 Description............................................................................. 786 Identification Chart ACD Group 0........................................................ 787 Identification Chart ACD Group 1........................................................ 788 Identification Chart ACD Group 2........................................................ 789 Identification Chart ACD Group 3........................................................ 790 ELECTRICAL / HYDRAULIC CONTROLS (SJC)....................................................... 791 Identification Chart.................................................................... 791 Description............................................................................. 792 Identification Chart ACD Group 0........................................................ 793 Identification Chart ACD Group 1........................................................ 794 Identification Chart ACD Group 2........................................................ 795 Identification Chart ACD Group 3........................................................ 796 SERVICE PC (LAPTOP COMPUTER)................................................................ 797 Connecting Remote Start Tool............................................................ 797 Connecting Remote Start Tool (Service Tool)............................................. 797 CALIBRATION................................................................................. 799 Description............................................................................. 799 Actuator Testing........................................................................ 799 Lift And Tilt Calibration (SJC)......................................................... 802 Hydrostatic Pump Calibration (SJC)...................................................... 804 Lift And Tilt Calibration (ACS)......................................................... 809 STEERING DRIFT COMPENSATION (OPERATOR MODE)................................................. 811 Description............................................................................. 811 Operation............................................................................... 811 STEERING DRIFT COMPENSATION (SERVICE MODE).................................................. 813 Description............................................................................. 813 Operation............................................................................... 813 CONTROL PANEL SETUP......................................................................... 815 Right Panel Setup (Deluxe Instrumentation Panel)........................................ 815 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)............................................... 819 Password Description.................................................................... 819 Changing The Owner Password............................................................. 819 Changing The User Passwords............................................................. 820 Password Lockout Feature................................................................ 820 PASSWORD SETUP (KEYLESS START PANEL)........................................................ 821 Password Description.................................................................... 821 Changing The Owner Password............................................................. 821 Password Lockout Feature................................................................ 821 MAINTENANCE CLOCK........................................................................... 823 Description............................................................................. 823 Setup................................................................................... 824 Reset................................................................................... 827 BACK-UP ALARM SYSTEM........................................................................ 829 Description............................................................................. 829 Inspecting.............................................................................. 829 Adjusting Switch Position............................................................... 830 Troubleshooting (Standard And ACS)...................................................... 831 Troubleshooting (Joystick).............................................................. 832 Alarm Removal And Installation.......................................................... 833 Switch Removal And Installation......................................................... 833 FRONT HORN.................................................................................. 835 Removal And Installation................................................................ 835 Troubleshooting......................................................................... 836 Troubleshooting (Joystick).............................................................. 837 ENGINE SPEED CONTROL (HAND)................................................................. 839 Removal And Installation................................................................ 839 ENGINE SPEED CONTROL (FOOT)................................................................. 841 Removal And Installation................................................................ 841 Disassembly And Assembly................................................................ 842 Pedal (Adjusting)....................................................................... 844 Floor Pan Removal And Installation...................................................... 844 CAMSHAFT AND CRANKSHAFT POSITION SENSOR..................................................... 845 Removal And Installation................................................................ 845 ENGINE SERVICE.................................................................................. 847 ENGINE INFORMATION.......................................................................... 851 Description............................................................................. 851 Specifications.......................................................................... 852 Sensor Location......................................................................... 854 Torque Values........................................................................... 860 Troubleshooting......................................................................... 862 Engine Removal And Installation......................................................... 864 Engine Mount Replacement................................................................ 874 Compression - Testing................................................................... 876 DIESEL OXIDATION CATALYST (DOC)............................................................. 879 Removal And Installation................................................................ 879 AIR CLEANER................................................................................. 881 Housing Removal And Installation........................................................ 881 ENGINE COOLING SYSTEM....................................................................... 883 Radiator / Oil Cooler Removal And Installation.......................................... 883 Hydraulic Fan Description............................................................... 886 Fan Duct Removal And Installation....................................................... 886 Hydraulic Fan Motor Assembly Removal And Installation................................... 887 Fan Removal And Installation............................................................ 888 Hydraulic Fan Motor Removal And Installation............................................ 889 Hydraulic Fan Motor Disassembly And Assembly............................................ 890 Fan Shroud Removal And Installation..................................................... 896 Water Pump Removal And Installation..................................................... 896 Thermostat Housing Removal And Installation............................................. 897 Testing The Thermostat.................................................................. 899 LUBRICATION SYSTEM.......................................................................... 901 Description............................................................................. 901 Oil Pan Removal And Installation........................................................ 902 Oil Pump Removal And Installation....................................................... 903 Oil Pump Relief Valve Description....................................................... 903 Oil Cooler Removal And Installation..................................................... 904 Oil Filter Head Removal And Installation................................................ 904 Oil Cooler Bypass Description........................................................... 904 FUEL SYSTEM................................................................................. 905 Description............................................................................. 905 Transfer Pump / High Pressure Pump Removal And Installation............................. 906 Fuel Cooler Removal And Installation.................................................... 909 Fuel Bypass Removal And Installation.................................................... 909 Fuel Injector Removal And Installation.................................................. 910 CYLINDER HEAD............................................................................... 913 Glow Plugs Testing...................................................................... 913 Glow Plug Removal And Installation...................................................... 914 Valve Clearance Adjustment.............................................................. 915 Cylinder Head Removal And Installation.................................................. 917 Cylinder Head Disassembly And Assembly.................................................. 922 Cylinder Head Inspection................................................................ 923 Cylinder Head Top Clearance............................................................. 924 Valve Step Height....................................................................... 925 Valve Stem Height....................................................................... 925 Valve Guide............................................................................. 926 Valve................................................................................... 926 Valve Spring............................................................................ 927 Rocker Arm Shaft Disassembly And Assembly............................................... 928 Rocker Arm Shaft Inspection............................................................. 929 Push Rod Inspection..................................................................... 929 CRANKSHAFT AND PISTONS...................................................................... 931 Piston And Connecting Rod Removal And Installation...................................... 931 Piston And Connecting Rod Inspection.................................................... 932 Crankshaft Removal And Installation..................................................... 934 Cylinder Block Inspection............................................................... 937 Crankshaft Inspection................................................................... 939 Connecting Rod Inspection............................................................... 939 Engine Component Class.................................................................. 940 CAMSHAFT.................................................................................... 943 Removal And Installation................................................................ 943 Inspecting.............................................................................. 944 GEARCASE.................................................................................... 947 Gearcase Cover Removal And Installation................................................. 947 Gear Backlash........................................................................... 948 Gear Timing............................................................................. 949 Idle Gear Removal And Installation...................................................... 950 Idle Gear Inspection.................................................................... 950 TURBOCHARGER................................................................................ 951 Description............................................................................. 951 Removal And Installation................................................................ 951 Inspection.............................................................................. 954 FLYWHEEL AND HOUSING........................................................................ 955 Flywheel Removal And Installation....................................................... 955 Ring Gear Removal And Installation...................................................... 956 Housing Removal And Installation........................................................ 956 EXHAUST GAS RECIRCULATION (EGR) SYSTEM...................................................... 957 Description............................................................................. 957 Removal And Installation................................................................ 958 Disassembly And Assembly................................................................ 962 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)................................................ 965 AIR CONDITIONING SYSTEM FLOW................................................................ 967 Description............................................................................. 967 Chart................................................................................... 968 Components.............................................................................. 969 Safety Equipment........................................................................ 972 REGULAR MAINTENANCE......................................................................... 973 Filters................................................................................. 973 Belt Adjustment......................................................................... 974 Belt Replacement........................................................................ 974 Air Conditioning Condenser.............................................................. 975 Air Conditioning Lubrication............................................................ 975 Air Conditioning Service Chart.......................................................... 976 Evaporator / Heater Coil................................................................ 977 TROUBLESHOOTING............................................................................. 979 Blower Motor Does Not Operate........................................................... 979 Blower Motor Operates Normally, But Air Flow Is Insufficient............................ 979 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal.............. 979 The Compressor Does Not Operate At All, Or Operates Improperly.......................... 979 Gauge Pressure Related Troubleshooting.................................................. 980 Troubleshooting Tree.................................................................... 982 Temperature / Pressure Chart............................................................ 986 Poor A/C Performance.................................................................... 988 HVAC Repair And Leaks................................................................... 989 Electrical System....................................................................... 990 Engine Coolant Bypassing The Heater Valve............................................... 996 Heater Valve Not Opening Or Closing..................................................... 997 SYSTEM CHARGING AND RECLAMATION............................................................. 999 Refrigerant Identification.............................................................. 999 Reclamation And Charging With Recovery / Charging Unit..................................1000 COMPRESSOR..................................................................................1003 Removal And Installation................................................................1003 Oil.....................................................................................1004 Oil Check...............................................................................1005 CONDENSER...................................................................................1007 Removal And Installation................................................................1007 RECEIVER / DRIER............................................................................1009 Receiver / Drier Removal And Installation...............................................1009 Pressure Switch Removal And Installation................................................1010 Schrader® Valve Removal And Installation................................................1011 EVAPORATOR / HEATER UNIT....................................................................1013 Removal And Installation................................................................1013 THERMOSTAT..................................................................................1015 Description.............................................................................1015 Removal And Installation................................................................1016 EXPANSION VALVE.............................................................................1017 Removal And Installation................................................................1017 EVAPORATOR COIL.............................................................................1019 Removal And Installation................................................................1019 HEATER COIL.................................................................................1021 Removal And Installation................................................................1021 BLOWER FAN..................................................................................1023 Removal And Installation................................................................1023 Disassembly And Assembly................................................................1023 HEATER VALVE................................................................................1027 Removal And Installation................................................................1027 EVAPORATOR / HEATER COVER...................................................................1029 Removing................................................................................1029 Installing..............................................................................1029 SPECIFICATIONS..................................................................................1031 (T450) LOADER SPECIFICATIONS................................................................1033 Machine Dimensions......................................................................1033 Performance.............................................................................1034 Engine..................................................................................1034 Drive System............................................................................1035 Controls................................................................................1035 Hydraulic System........................................................................1036 Electrical System.......................................................................1037 Capacities..............................................................................1037 Tracks..................................................................................1038 Ground Pressure.........................................................................1038 TECHNICAL SERVICE GUIDE SPECIFICATIONS......................................................1039 Engine..................................................................................1039 Engine Torques..........................................................................1039 Cooling System..........................................................................1039 Loader Torques..........................................................................1040 Hydraulic / Hydrostatic System..........................................................1040 Fuel Consumption........................................................................1040 TORQUE SPECIFICATIONS FOR BOLTS.............................................................1041 Torque For General SAE Bolts............................................................1041 Torque For General Metric Bolts.........................................................1042 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................1043 Straight Thread O-ring Fitting..........................................................1043 Flare Fitting...........................................................................1044 Tubelines And Hoses.....................................................................1044 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................1045 Specifications..........................................................................1045 CONVERSIONS.................................................................................1047 Decimal And Millimeter Equivalent Chart.................................................1047 U.S. To Metric Conversion Chart.........................................................1047 SERVICE TOOLS REQUIRED......................................................................1049 Remote Start Tools......................................................................1049 Hydraulic Tools.........................................................................1050 Mainframe And Drive Tools...............................................................1053 Electrical Tools........................................................................1056 Engine Tools............................................................................1057 HVAC Tools..............................................................................1062 ALPHABETICAL INDEX..............................................................................1063
Customer Support: [email protected]
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.V
