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Bobcat T550 Compact Track Loader Service Manual SN A7UJ11001 & Above – PDF DOWNLOAD
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Bobcat T550 Compact Track Loader Service Manual SN A7UJ11001 & Above – PDF DOWNLOAD
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Description
Bobcat T550 Compact Track Loader Service Manual SN A7UJ11001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat T550 Compact Track Loader Service Manual SN A7UJ11001 & Above – PDF DOWNLOAD
Language : English
Pages : 976
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T550 Compact Track Loader Service Manual SN A7UJ11001 & 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 wedges and linkages must function correctly and be in good condition.
12. Safety treads must be in good condition.
13. Check for correct function of indicator lamps.
14. Check hydraulic fluid level, engine oil level and fuel supply.
15. Inspect for fuel, oil or hydraulic fluid leaks.
SAFETY INSTRUCTIONS:
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
• The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
• The AEM Safety Manual delivered with the machine gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
TABLE OF CONTENTS:
Bobcat T550 Compact Track Loader Service Manual SN A7UJ11001 & Above – PDF DOWNLOAD
MAINTENANCE SAFETY.............................................................................. 3 CONTENTS........................................................................................ 5 FOREWORD........................................................................................ 7 FOREWORD.................................................................................... 9 SAFETY INSTRUCTIONS......................................................................... 11 FIRE PREVENTION............................................................................. 13 Maintenance............................................................................. 13 Operation............................................................................... 13 Electrical.............................................................................. 13 Hydraulic System........................................................................ 13 Fueling................................................................................. 13 Starting................................................................................ 13 Spark Arrester Exhaust System........................................................... 13 Welding And Grinding.................................................................... 14 Fire Extinguishers...................................................................... 14 SERIAL NUMBER LOCATIONS..................................................................... 15 Loader Serial Number.................................................................... 15 Engine Serial Number.................................................................... 15 DELIVERY REPORT............................................................................. 16 LOADER IDENTIFICATION....................................................................... 17 SAFETY AND MAINTENANCE.......................................................................... 19 LIFTING AND BLOCKING THE LOADER............................................................. 23 Procedure............................................................................... 23 LIFT ARM SUPPORT DEVICE..................................................................... 25 Description............................................................................. 25 Installing.............................................................................. 26 Removing................................................................................ 27 OPERATOR CAB................................................................................ 29 Description............................................................................. 29 Raising................................................................................. 30 Lowering................................................................................ 31 Cab Door Sensor......................................................................... 32 Special Applications Kit................................................................ 32 Special Applications Kit Inspection And Maintenance..................................... 32 Forestry Door And Window Kit............................................................ 33 Forestry Door And Window Kit Inspection And Maintenance................................. 33 TRANSPORTING THE LOADER ON A TRAILER........................................................ 35 Loading And Unloading................................................................... 35 Fastening............................................................................... 35 TOWING THE LOADER........................................................................... 37 Procedure............................................................................... 37 REMOTE START TOOL KIT- MEL1563.............................................................. 39 Remote Start Tool - MEL1563............................................................. 39 Service Tool Harness Communicator - MEL1566............................................. 41 Remote Start Procedure.................................................................. 41 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666.............................................. 45 Description............................................................................. 45 Remote Start Tool (Service Tool) - 7022042.............................................. 46 Loader Service Tool Harness - 6689747................................................... 47 Computer Service Tool Harness - 6689746................................................. 48 Remote Start Procedure.................................................................. 49 SERVICE SCHEDULE............................................................................ 53 Maintenance Intervals................................................................... 53 ENGINE AIR CLEANER.......................................................................... 55 Replacing Filters....................................................................... 55 ENGINE COOLING SYSTEM (EARLY MODELS)........................................................ 57 Maintenance Platform.................................................................... 57 Cleaning................................................................................ 57 Checking And Adding Coolant............................................................. 59 Removing And Replacing Coolant.......................................................... 60 ENGINE COOLING SYSTEM (LATER MODELS)........................................................ 61 Maintenance Platform.................................................................... 61 Cleaning................................................................................ 61 Checking And Adding Coolant............................................................. 63 Removing And Replacing Coolant.......................................................... 64 FUEL SYSTEM................................................................................. 65 Fuel Specifications..................................................................... 65 Biodiesel Blend Fuel.................................................................... 65 Filling The Fuel Tank................................................................... 66 Fuel Filter............................................................................. 67 Removing Air From The Fuel System....................................................... 68 ENGINE LUBRICATION SYSTEM................................................................... 69 Checking And Adding Engine Oil.......................................................... 69 Engine Oil Chart........................................................................ 69 Removing And Replacing Oil And Filter................................................... 70 HYDRAULIC / HYDROSTATIC SYSTEM.............................................................. 71 Checking And Adding Fluid............................................................... 71 Hydraulic / Hydrostatic Fluid Chart..................................................... 71 Removing And Replacing Hydraulic Fluid.................................................. 72 Removing And Replacing Hydraulic / Hydrostatic Filter................................... 74 Removing And Replacing Hydraulic Charge Filter.......................................... 75 Replacing Reservoir Breather Cap........................................................ 77 BOB-TACH (HAND LEVER)....................................................................... 79 Inspection And Maintenance.............................................................. 79 BOB-TACH (POWER)............................................................................ 81 Inspection And Maintenance.............................................................. 81 LUBRICATING THE LOADER...................................................................... 83 Lubrication Locations................................................................... 83 SPARK ARRESTER MUFFLER...................................................................... 87 Cleaning Procedure...................................................................... 87 PIVOT PINS.................................................................................. 89 Inspection And Maintenance.............................................................. 89 LOADER STORAGE AND RETURN TO SERVICE........................................................ 91 Storage................................................................................. 91 Return To Service....................................................................... 91 STOPPING THE ENGINE AND LEAVING THE LOADER.................................................. 93 Procedure............................................................................... 93 EMERGENCY EXIT.............................................................................. 95 Rear Window Identification.............................................................. 95 Rear Window Removal (Latches)........................................................... 95 Rear Window Removal (Rubber Cord)....................................................... 95 External Access (Rear Window With Latches).............................................. 96 External Access (Rear Window With Rubber Cord).......................................... 96 Front Door.............................................................................. 96 SEAT BELT................................................................................... 99 Inspection And Maintenance.............................................................. 99 HYDRAULIC SYSTEM................................................................................101 HYDRAULIC/HYDROSTATIC SCHEMATICS............................................................105 HYDRAULIC SYSTEM INFORMATION................................................................113 Glossary Of Hydraulic / Hydrostatic Symbols.............................................113 Troubleshooting.........................................................................117 CYLINDER (LIFT).............................................................................119 Testing.................................................................................119 Removal And Installation................................................................120 Parts Identification....................................................................123 Disassembly.............................................................................124 Assembly................................................................................126 CYLINDER (TILT).............................................................................129 Testing.................................................................................129 Removal And Installation................................................................130 Base End Pivot Pin Removal And Installation.............................................131 Parts Identification....................................................................132 Disassembly.............................................................................133 Assembly................................................................................135 CYLINDER (BOB-TACH).........................................................................139 Testing.................................................................................139 Removal And Installation................................................................140 Parts Identification....................................................................141 Disassembly.............................................................................142 Assembly................................................................................143 MAIN RELIEF VALVE...........................................................................147 Description.............................................................................147 Testing.................................................................................148 Adjusting...............................................................................150 Removal And Installation................................................................151 HYDRAULIC CONTROL VALVE (STANDARD)..........................................................153 Description.............................................................................153 Removal And Installation................................................................154 Mount Bracket Removal And Installation..................................................157 Identification Chart....................................................................158 Lift Load Check Valve Removal And Installation..........................................159 Load Check Valve Removal And Installation (Tilt And Auxiliary)..........................160 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................161 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........161 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........162 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............162 Port Relief Valve Removal And Installation..............................................163 Plug Removal And Installation...........................................................165 Rubber Boot Removal And Installation....................................................166 End Cap Block Removal And Installation..................................................166 Lift Spool And Detent Removal And Installation..........................................167 Tilt Spool Removal And Installation.....................................................175 Auxiliary Spool Removal And Installation................................................177 Auxiliary Solenoid Removal And Installation.............................................178 Solenoid Removal And Installation.......................................................179 Lock Valve Removal And Installation.....................................................180 Lift Arm Bypass Orifice Removal And Installation........................................182 Main Relief Valve Removal And Installation..............................................182 Check Valve Removal And Installation....................................................183 HYDRAULIC CONTROL VALVE (ACS) OR (SJC)......................................................185 Description.............................................................................185 Removal And Installation................................................................185 Actuator Removal And Installation (In Loader)...........................................189 Actuator Removal And Installation (Out Of Loader).......................................191 Identification Chart....................................................................194 Mount Bracket Removal And Installation..................................................195 Lift Load Check Valve Removal And Installation..........................................195 Load Check Valve Removal And Installation (Tilt And Auxiliary)..........................196 Anti-Cavitation Valve Removal And Installation (Lift, Rod End)..........................197 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)...........197 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)...........198 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............198 Port Relief Valve Removal And Installation..............................................199 Plug Removal And Installation...........................................................201 End Cap Block Removal And Installation..................................................202 Lift Spool Removal And Installation.....................................................202 Lift Spool Disassembly And Assembly.....................................................204 Tilt Spool Removal And Installation.....................................................205 Auxiliary Spool Removal And Installation................................................207 Auxiliary Solenoid Removal And Installation.............................................208 Solenoid Removal And Installation.......................................................209 Lock Valve Removal And Installation.....................................................210 Lift Arm Bypass Orifice Removal And Installation........................................212 Main Relief Valve Removal And Installation..............................................212 Check Valve Removal And Installation....................................................213 LIFT ARM BYPASS CONTROL VALVE...............................................................215 Description.............................................................................215 Testing.................................................................................215 Removal And Installation................................................................216 Bracket Removal And Installation........................................................217 Disassembly And Assembly................................................................217 HYDRAULIC PUMP..............................................................................219 Description.............................................................................219 Pump Test At Quick Couplers.............................................................220 Direct Pump Test (Standard Section).....................................................222 Direct Pump Test (Charge Section).......................................................224 Removal And Installation................................................................226 Hydraulic Pump Startup..................................................................228 Parts Identification....................................................................229 Disassembly And Assembly................................................................230 HYDRAULIC PUMP (HIGH FLOW)..................................................................231 Description.............................................................................231 Pump Test At Quick Couplers.............................................................232 Direct Pump Test (Standard Section).....................................................234 Direct Pump Test (Charge Section).......................................................236 Direct Pump Test (High Flow Section)....................................................238 High Flow Relief Valve Adjustment.......................................................240 High Flow Relief Valve Removal And Installation.........................................241 Solenoid Removal And Installation.......................................................242 Removal And Installation................................................................243 Hydraulic Pump Startup..................................................................245 Parts Identification....................................................................246 Disassembly And Assembly................................................................247 HYDRAULIC / HYDROSTATIC FILTERS.............................................................249 Description.............................................................................249 Housing Removal And Installation........................................................249 HYDRAULIC FLUID RESERVOIR...................................................................251 Description.............................................................................251 Removal And Installation................................................................251 Hydraulic Fluid Screen..................................................................252 OIL COOLER (EARLY MODELS)...................................................................253 Description.............................................................................253 Removal And Installation................................................................253 OIL COOLER (LATER MODELS)...................................................................255 Removal And Installation................................................................255 BUCKET POSITION VALVE.......................................................................257 Description.............................................................................257 Solenoid Removal And Installation.......................................................257 Solenoid Testing........................................................................258 Removal And Installation................................................................259 Disassembly And Assembly................................................................261 REAR AUXILIARY DIVERTER VALVE...............................................................263 Description.............................................................................263 Solenoid Testing........................................................................263 Removal And Installation................................................................264 Disassembly And Assembly................................................................265 BOB-TACH (POWER) BLOCK (EARLY MODELS).......................................................271 Description.............................................................................271 Removal And Installation................................................................271 Disassembly And Assembly................................................................273 BOB-TACH (POWER) BLOCK (later models).......................................................281 Description.............................................................................281 Testing Relief Valve....................................................................282 Removal And Installation................................................................284 Disassembly And Assembly................................................................286 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK.....................................................291 Description.............................................................................291 Removal And Installation................................................................292 Disassembly And Assembly (FFI/FI).......................................................292 Disassembly And Assembly (FFH/FH).......................................................294 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................................................................304 Parts Identification....................................................................306 Disassembly.............................................................................308 Assembly................................................................................316 CHARGE PRESSURE.............................................................................325 Description.............................................................................325 Testing.................................................................................326 Adjusting...............................................................................327 Sender Removal And Installation.........................................................329 HYDROSTATIC PUMP............................................................................331 Description.............................................................................331 Removal And Installation................................................................332 Hydrostatic Pump Startup................................................................333 Replenishing / High Pressure Relief Valve Removal And Installation......................334 Parts Identification (Left Half)........................................................335 Parts Identification (Right Half).......................................................336 Disassembly.............................................................................337 Assembly................................................................................344 HYDROSTATIC PUMP (SJC)......................................................................351 Description.............................................................................351 Hydraulic Controller Removal And Installation...........................................352 Removal And Installation................................................................354 Hydrostatic Pump Startup................................................................356 Parts Identification....................................................................357 High Pressure Relief And Bypass Valve...................................................358 Charge Relief Valve.....................................................................359 Disassembly And Assembly................................................................360 Mechanical Neutral Adjustment...........................................................373 Hydraulic Controller Neutral Adjustment.................................................376 DRIVE BELT..................................................................................379 Belt Adjustment.........................................................................379 Belt Replacement........................................................................380 DRAIN MANIFOLD..............................................................................383 Description.............................................................................383 Drain Manifold Removal And Installation.................................................383 DRIVE SYSTEM....................................................................................385 BRAKE.......................................................................................387 Description.............................................................................387 Block Removal And Installation..........................................................387 Block Disassembly And Assembly..........................................................389 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED)..............................................391 Description.............................................................................391 Checking Tension........................................................................392 Adjusting Tension.......................................................................393 Track Removal And Installation..........................................................394 Idler (Front) Removal And Installation..................................................396 Track Tensioner Disassembly And Assembly................................................399 Idler (Rear) Removal And Installation...................................................401 Roller Removal And Installation.........................................................401 Sprocket Removal And Installation.......................................................402 Track Housing Removal And Installation..................................................403 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION)..........................................405 Description.............................................................................405 Checking Tension........................................................................406 Adjusting Tension.......................................................................407 Track Removal And Installation..........................................................408 Idler (Front) Removal And Installation..................................................410 Track Tensioner Disassembly And Assembly................................................413 Idler (Rear) Removal And Installation...................................................415 Leaf Spring Removal And Installation....................................................416 Sprocket Removal And Installation.......................................................417 Track Housing Removal And Installation..................................................418 TRACK MAINTENANCE...........................................................................421 Track Damage Identification.............................................................421 MAINFRAME.......................................................................................433 SEAT BAR....................................................................................437 Description.............................................................................437 Removal And Installation................................................................437 Disassembly And Assembly................................................................438 Compression Spring Disassembly And Assembly.............................................439 OPERATOR CAB................................................................................441 Gas Spring Removal And Installation.....................................................441 Gas Spring Bracket Disassembly And Assembly.............................................442 Removal And Installation................................................................442 OPERATOR SEAT (SUSPENSION)..................................................................445 Removal And Installation................................................................445 Slide Rail Removal And Installation.....................................................445 Seat Belt Removal And Installation......................................................446 Lower Cushion Removal...................................................................446 Lower Cushion Installation..............................................................447 Back Cushion Removal And Installation...................................................447 Shock Removal And Installation..........................................................448 3-Point Seat Belt Removal And Installation..............................................448 BOB-TACH (HAND LEVER).......................................................................451 Description.............................................................................451 Removal And Installation................................................................451 Lever And Wedge Disassembly And Assembly................................................453 Pivot Pin Bushing And Seal Removal And Installation.....................................455 BOB-TACH (POWER)............................................................................457 Description.............................................................................457 Removal And Installation................................................................457 Lever And Wedge Disassembly And Assembly................................................460 Pivot Pin Bushing And Seal Removal And Installation.....................................462 LIFT ARMS...................................................................................463 Removal And Installation................................................................463 REAR GRILLE.................................................................................465 Removing................................................................................465 Installing..............................................................................465 REAR DOOR (TAILGATE)........................................................................467 Removal And Installation................................................................467 Striker Removal And Installation........................................................468 Striker Disassembly And Assembly........................................................468 Striker (Adjusting).....................................................................469 Latch Removal And Installation..........................................................469 FUEL TANK...................................................................................471 Removal And Installation................................................................471 Fuel Level Sender Removal And Installation..............................................474 Fuel Fill Screen Removal And Installation...............................................474 CONTROL PEDALS AND LINKAGES.................................................................475 Description.............................................................................475 Pedal Removal And Installation..........................................................475 Linkage Removal And Installation........................................................476 Pedal (Adjusting).......................................................................477 Floor Pan Removal And Installation......................................................478 CONTROL PEDALS AND LINKAGES (ACS)...........................................................479 Description.............................................................................479 Pedal Removal And Installation..........................................................479 Linkage Removal And Installation........................................................480 Pedal (Adjusting).......................................................................480 Floor Pan Removal And Installation......................................................481 CONTROL PANEL...............................................................................483 Description.............................................................................483 Removal And Installation................................................................484 Disassembly And Assembly................................................................485 Linkage Removal And Installation........................................................487 Pintle Arm Disassembly And Assembly.....................................................491 Linkage Neutral (Adjusting).............................................................492 Linkage Travel (Adjusting)..............................................................496 Shock Removal And Installation..........................................................500 CONTROL PANEL (SJC).........................................................................501 Description.............................................................................501 Removal And Installation................................................................501 CONTROL HANDLE / LEVER......................................................................503 Description.............................................................................503 Lever Removal And Installation..........................................................503 Boot Removal And Installation...........................................................504 CONTROL HANDLE / LEVER (ACS)................................................................505 Description.............................................................................505 Handle Sensor Removal And Installation..................................................505 Handle Removal And Installation.........................................................508 Handle Disassembly And Assembly.........................................................509 Lever Removal And Installation..........................................................509 Boot Removal And Installation...........................................................510 CONTROL HANDLE / LEVER (SJC)................................................................511 Description.............................................................................511 Joystick Testing........................................................................511 Joystick Removal And Installation.......................................................512 ACCESS PANEL (INSIDE).......................................................................513 Removal And Installation (Left).........................................................513 Removal And Installation (Right)........................................................513 ACCESS PANEL (INSIDE) (SJC).................................................................515 Removal And Installation (Left).........................................................515 Removal And Installation (Right)........................................................515 WINDOW (REAR)...............................................................................517 Removal And Installation................................................................517 Rear Window Removal (Latches)...........................................................517 Rear Window Removal (Rubber Cord).......................................................518 External Access (Rear Window With Latches)..............................................518 External Access (Rear Window With Rubber Cord)..........................................519 Disassembly And Assembly (Rear Window With Latches).....................................519 WINDOW (TOP)................................................................................521 Removal And Installation................................................................521 WINDOW (SIDE)...............................................................................523 Removal And Installation................................................................523 CAB DOOR....................................................................................525 Description.............................................................................525 Removal And Installation................................................................525 Disassembly And Assembly................................................................526 Aligning................................................................................527 Adjusting...............................................................................528 Checking Operation......................................................................528 ARMREST.....................................................................................529 Description.............................................................................529 Removal And Installation................................................................530 Disassembly And Assembly................................................................531 LEFT SIDE LOWER PANEL.......................................................................533 Removal And Installation................................................................533 Disassembly And Assembly................................................................535 RIGHT SIDE LOWER PANEL......................................................................537 Removal And Installation................................................................537 Disassembly And Assembly................................................................538 HEADLINER...................................................................................541 Removal And Installation................................................................541 ELECTRICAL SYSTEM AND ANALYSIS..................................................................543 ELECTRICAL SCHEMATICS.......................................................................547 ELECTRICAL SYSTEM INFORMATION...............................................................579 Glossary Of Electrical Symbols..........................................................579 Standard Cab Harness Connectors.........................................................582 Deluxe Cab Harness Connectors...........................................................583 Mainframe Harness Connectors - Manual Controls..........................................584 Mainframe Harness Connectors - SJC......................................................585 Description.............................................................................586 Troubleshooting.........................................................................587 Fuse And Relay Location / Identification................................................588 Solenoid Testing........................................................................590 BATTERY.....................................................................................591 Removal And Installation................................................................591 Servicing...............................................................................592 Using A Booster Battery (Jump Starting).................................................593 ALTERNATOR..................................................................................595 Belt Adjustment.........................................................................595 Belt Replacement........................................................................595 Charging System Inspection..............................................................596 Alternator Voltage Testing..............................................................597 Low Voltage Testing.....................................................................597 High Voltage Testing....................................................................598 Removal And Installation................................................................599 Parts Identification....................................................................601 STARTER.....................................................................................603 Testing.................................................................................603 Removal And Installation................................................................603 Parts Identification....................................................................604 INSTRUMENT PANELS...........................................................................605 Left Panel..............................................................................605 Display Screen..........................................................................607 Right Panel (Standard Key Panel)........................................................608 Right Panel (Keyless Start Panel).......................................................609 Right Panel (Deluxe Instrumentation Panel)..............................................610 Left Switch Panel.......................................................................612 Right Switch Panel......................................................................612 Left Side Lower Panel...................................................................613 Right Side Lower Panel..................................................................613 Left Panel Removal And Installation.....................................................614 Right Panel (Standard Key Panel) Removal And Installation...............................614 Right Panel (Keyless Start Panel) Removal And Installation..............................615 Right Panel (Deluxe Instrumentation Panel) Removal And Installation.....................615 Key Switch Disassembly And Assembly.....................................................616 Alarm Disassembly And Assembly..........................................................616 Left Switch Panel Removal And Installation..............................................617 Right Switch Panel Removal And Installation.............................................617 LIGHTS......................................................................................619 Front Removal And Installation..........................................................619 Rear Removal And Installation...........................................................620 Cab Light Removal And Installation......................................................620 BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY)..................................................621 Description.............................................................................621 Connector Identification................................................................622 Removal And Installation................................................................628 BOBCAT CONTROLLER (ACS).....................................................................629 Description.............................................................................629 Connector And Wire Identification.......................................................630 Removal And Installation................................................................631 BOBCAT CONTROLLER (SJC) (DRIVE).............................................................633 Description.............................................................................633 Connector Identification................................................................634 Removal And Installation................................................................636 DIAGNOSTIC SERVICE CODES....................................................................637 Viewing Service Codes...................................................................637 Service Codes List......................................................................638 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™).....................................................645 Description.............................................................................645 Inspecting The BICS™ (Engine STOPPED - Key ON)..........................................646 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)....646 Inspecting The Seat Bar Sensor (Engine RUNNING).........................................646 Inspecting The Traction Lock (Engine RUNNING)...........................................646 Inspecting The Lift Arm Bypass Control..................................................646 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)........................646 Troubleshooting.........................................................................647 SEAT BAR SENSOR.............................................................................649 Description.............................................................................649 Troubleshooting.........................................................................649 Testing.................................................................................650 Removal.................................................................................651 Installation............................................................................653 Bobcat Interlock Control System (BICS™) Circuit Test....................................654 TRACTION LOCK...............................................................................657 Description.............................................................................657 Troubleshooting.........................................................................658 Inspecting..............................................................................659 CONTROL SYSTEM (ACS)........................................................................661 Description.............................................................................661 Troubleshooting.........................................................................662 Handle Sensor Connector Disassembly And Assembly........................................663 Switch Handle Removal...................................................................664 Switch Handle Installation..............................................................666 Actuator Connector Disassembly And Assembly.............................................669 Handle Lock Solenoid Removal And Installation...........................................670 Handle Lock Solenoid Disassembly And Assembly...........................................670 Foot Sensor Removal And Installation....................................................671 Foot Sensor Disassembly And Assembly....................................................672 Foot Sensor Lock Solenoid Removal And Installation......................................672 ELECTRICAL / HYDRAULIC CONTROLS.............................................................673 Identification Chart....................................................................673 Description.............................................................................674 Identification Chart ACD Group 0........................................................675 Identification Chart ACD Group 1........................................................676 Identification Chart ACD Group 2........................................................677 Identification Chart ACD Group 3........................................................678 ELECTRICAL / HYDRAULIC CONTROLS (ACS).......................................................679 Identification Chart....................................................................679 Description.............................................................................680 Identification Chart ACD Group 0........................................................681 Identification Chart ACD Group 1........................................................682 Identification Chart ACD Group 2........................................................683 Identification Chart ACD Group 3........................................................684 ELECTRICAL / HYDRAULIC CONTROLS (SJC).......................................................685 Identification Chart....................................................................685 Description.............................................................................686 Identification Chart ACD Group 0........................................................687 Identification Chart ACD Group 1........................................................688 Identification Chart ACD Group 2........................................................689 Identification Chart ACD Group 3........................................................690 SERVICE PC (LAPTOP COMPUTER)................................................................691 Connecting Remote Start Tool............................................................691 Connecting Remote Start Tool (Service Tool).............................................691 CALIBRATION.................................................................................693 Description.............................................................................693 Actuator Testing........................................................................693 Lift And Tilt Calibration (SJC).........................................................696 Hydrostatic Pump Calibration (SJC)......................................................698 Lift And Tilt Calibration (ACS).........................................................703 STEERING DRIFT COMPENSATION (operator mode).................................................705 Description.............................................................................705 Operation...............................................................................705 STEERING DRIFT COMPENSATION (service mode)..................................................707 Description.............................................................................707 Operation...............................................................................707 FLYWHEEL RPM SENSOR.........................................................................709 Description.............................................................................709 Removal.................................................................................709 Installation............................................................................710 CONTROL PANEL SETUP.........................................................................711 Right Panel Setup (Deluxe Instrumentation Panel)........................................711 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...............................................715 Password Description....................................................................715 Changing The Owner Password.............................................................715 Changing The User Passwords.............................................................716 Password Lockout Feature................................................................716 PASSWORD SETUP (KEYLESS START PANEL)........................................................717 Password Description....................................................................717 Changing The Owner Password.............................................................717 Password Lockout Feature................................................................717 MAINTENANCE CLOCK...........................................................................719 Description.............................................................................719 Setup...................................................................................720 Reset...................................................................................723 BACK-UP ALARM SYSTEM........................................................................725 Description.............................................................................725 Inspection..............................................................................725 Adjusting Switch Position...............................................................726 Troubleshooting (Standard And ACS)......................................................727 Troubleshooting (Joystick)..............................................................728 Alarm Removal And Installation..........................................................729 Switch Removal And Installation.........................................................729 FRONT HORN..................................................................................731 Removal And Installation................................................................731 Troubleshooting.........................................................................732 Troubleshooting (Joystick)..............................................................733 ENGINE SERVICE..................................................................................735 ENGINE INFORMATION..........................................................................739 Description.............................................................................739 Specifications..........................................................................740 Torque Values...........................................................................743 Troubleshooting.........................................................................743 Engine Removal And Installation.........................................................745 Engine Mount Replacement................................................................754 Compression - Testing...................................................................755 ENGINE SPEED CONTROL (HAND).................................................................757 Removal And Installation................................................................757 Disassembly And Assembly................................................................757 Cable Removal And Installation..........................................................758 ENGINE SPEED CONTROL (FOOT).................................................................759 Removal And Installation................................................................759 Disassembly And Assembly................................................................760 MUFFLER.....................................................................................763 Removal And Installation................................................................763 AIR CLEANER.................................................................................765 Housing Removal And Installation........................................................765 ENGINE COOLING SYSTEM (EARLY MODELS)........................................................767 Radiator Removal And Installation.......................................................767 Hydraulic Fan Description...............................................................769 Fan Duct Removal And Installation.......................................................769 Hydraulic Fan Motor Assembly Removal And Installation...................................770 Hydraulic Fan Motor Removal And Installation............................................771 Hydraulic Fan Motor Disassembly And Assembly............................................773 Blower Housing Removal And Installation.................................................774 Water Pump Removal And Installation.....................................................775 Water Pump Disassembly And Assembly.....................................................775 Thermostat Housing Removal And Installation.............................................776 Thermostat - Testing....................................................................777 ENGINE COOLING SYSTEM (LATER MODELS)........................................................779 Radiator / Oil Cooler Removal And Installation..........................................779 Hydraulic Fan Description...............................................................782 Fan Duct Removal And Installation.......................................................782 Hydraulic Fan Motor Assembly Removal And Installation...................................783 Fan Removal And Installation............................................................784 Hydraulic Fan Motor Removal And Installation............................................785 Hydraulic Fan Disassembly And Assembly..................................................786 Blower Housing Removal And Installation.................................................791 Water Pump Removal And Installation.....................................................792 Water Pump Disassembly And Assembly.....................................................792 Thermostat Housing Removal And Installation.............................................793 Thermostat - Testing....................................................................794 LUBRICATION SYSTEM..........................................................................795 Oil Pan Removal And Installation........................................................795 Oil Pump Removal And Installation.......................................................795 Relief Valve - Testing..................................................................796 Oil Pump Inspection.....................................................................796 Oil Filter Cooler Removal And Installation..............................................797 Engine Oil Pressure - Testing...........................................................798 FUEL SYSTEM.................................................................................799 Fuel Shutoff Solenoid - Testing.........................................................799 Fuel Shutoff Solenoid Removal And Installation..........................................799 Fuel Injection Pump - Testing...........................................................800 Fuel Injection Pump Assembly Removal And Installation...................................801 Governor Housing Disassembly And Assembly...............................................804 Governor Disassembly And Assembly.......................................................806 Fuel Camshaft Removal And Installation..................................................808 Fuel Injection Pump Removal And Installation............................................811 Fuel Injection Pump - Timing............................................................813 Fuel Injector Removal And Installation..................................................815 Fuel Injector Nozzle Pressure - Testing.................................................816 Nozzle Spray Condition..................................................................817 Valve Seat Tightness....................................................................817 CYLINDER HEAD...............................................................................819 Glow Plugs - Testing....................................................................819 Glow Plugs Removal And Installation.....................................................819 Valve Clearance Adjustment..............................................................820 Valve Timing - Inspecting...............................................................821 Cylinder Head Removal And Installation..................................................822 Cylinder Head Disassembly And Assembly..................................................825 Cylinder Head - Servicing...............................................................826 Cylinder Head Top Clearance.............................................................827 Valve Guide - Inspecting................................................................828 Valve Guide Removal And Installation....................................................828 Reconditioning The Valve And Valve Seat.................................................829 Valve Spring............................................................................831 Valve Tappets...........................................................................832 Rocker Arm And Shaft - Inspecting.......................................................833 Bridge Arm And Bridge Arm Shaft - Inspecting............................................833 Bridge Arm Shaft - Removal And Installation.............................................834 Push Rod Alignment - Inspecting.........................................................835 CRANKSHAFT AND PISTONS......................................................................837 Piston And Connecting Rod Removal And Installation......................................837 Piston And Connecting Rod - Servicing...................................................838 Cylinder Bore - Inspecting..............................................................842 Connecting Rod Alignment................................................................842 Crankshaft Gear Removal And Installation................................................843 Crankshaft And Bearings Removal And Installation........................................844 Crankshaft And Bearings - Servicing.....................................................847 CAMSHAFT AND TIMING GEARS...................................................................851 Timing Gearcase Cover Removal...........................................................851 Timing Gearcase Cover Installation......................................................852 Timing Gears Backlash - Inspection......................................................855 Idler Gear And Camshaft Removal And Installation........................................855 Camshaft - Servicing....................................................................856 Idler Gear And Shaft - Servicing........................................................857 TURBOCHARGER................................................................................859 Description.............................................................................859 Testing.................................................................................859 Removal And Installation................................................................860 FLYWHEEL AND HOUSING........................................................................861 Flywheel Removal And Installation.......................................................861 Ring Gear Removal And Installation......................................................862 Housing Removal And Installation........................................................863 EXHAUST GAS RECIRCULATION (EGR) SYSTEM......................................................865 Description.............................................................................865 Testing.................................................................................866 Removal And Installation................................................................869 Disassembly And Assembly................................................................870 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)................................................871 AIR CONDITIONING SYSTEM FLOW................................................................873 Description.............................................................................873 Chart...................................................................................874 Components..............................................................................875 Safety Equipment........................................................................878 REGULAR MAINTENANCE.........................................................................879 Filters.................................................................................879 Belt Adjustment.........................................................................880 Belt Replacement........................................................................880 Air Conditioning Condenser..............................................................880 Air Conditioning Lubrication............................................................880 Air Conditioning Service Chart..........................................................881 Evaporator / Heater Coil................................................................882 TROUBLESHOOTING.............................................................................885 Blower Motor Does Not Operate...........................................................885 Blower Motor Operates Normally, But Air Flow Is Insufficient............................885 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............885 The Compressor Does Not Operate At All, Or Operates Improperly..........................885 Gauge Pressure Related Troubleshooting..................................................886 Troubleshooting Tree....................................................................888 Temperature / Pressure Chart............................................................892 Poor A/C Performance....................................................................894 HVAC Repair And Leaks...................................................................895 Electrical System.......................................................................896 Engine Coolant Bypassing The Heater Valve...............................................902 Heater Valve Not Opening Or Closing.....................................................903 SYSTEM CHARGING AND RECLAMATION.............................................................905 Refrigerant Identification..............................................................905 Reclamation And Charging With Recovery / Charging Unit..................................906 COMPRESSOR..................................................................................909 Removal And Installation................................................................909 Oil.....................................................................................910 Oil Check...............................................................................911 CONDENSER (EARLY MODELS)....................................................................913 Removal And Installation................................................................913 CONDENSER (LATER MODELS)....................................................................915 Removal And Installation................................................................915 RECEIVER / DRIER (EARLY MODELS).............................................................917 Receiver / Drier Removal And Installation...............................................917 Pressure Relief Valve Removal And Installation..........................................918 Pressure Switch Removal And Installation................................................919 Schraeder® Valve Removal And Installation...............................................920 RECEIVER / DRIER (LATER MODELS).............................................................921 Receiver / Drier Removal And Installation...............................................921 Pressure Switch Removal And Installation................................................923 Schraeder® Valve Removal And Installation...............................................924 EVAPORATOR / HEATER UNIT....................................................................925 Removal And Installation................................................................925 THERMOSTAT..................................................................................927 Description.............................................................................927 Removal And Installation................................................................928 EXPANSION VALVE.............................................................................929 Removal And Installation................................................................929 EVAPORATOR COIL.............................................................................931 Removal And Installation................................................................931 HEATER COIL.................................................................................933 Removal And Installation................................................................933 BLOWER FAN..................................................................................935 Removal And Installation................................................................935 Disassembly And Assembly................................................................935 HEATER VALVE................................................................................939 Removal And Installation................................................................939 EVAPORATOR / HEATER COVER...................................................................941 Removing................................................................................941 Installing..............................................................................941 SPECIFICATIONS..................................................................................943 (T550) LOADER SPECIFICATIONS................................................................945 Machine Dimensions......................................................................945 Performance.............................................................................946 Engine..................................................................................946 Drive System............................................................................947 Controls................................................................................947 Hydraulic System........................................................................948 Electrical System.......................................................................949 Capacities..............................................................................949 Tracks..................................................................................950 Ground Pressure.........................................................................950 TECHINCAL SERVICE GUIDE SPECIFICATIONS......................................................951 Engine..................................................................................951 Engine Torques..........................................................................951 Cooling System..........................................................................951 Loader Torques..........................................................................952 Hydraulic / Hydrostatic System..........................................................952 Fuel Consumption........................................................................952 TORQUE SPECIFICATIONS FOR BOLTS.............................................................953 Torque For General SAE Bolts............................................................953 Torque For General Metric Bolts.........................................................954 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................955 Straight Thread O-ring Fitting..........................................................955 Flare Fitting...........................................................................956 Tubelines And Hoses.....................................................................956 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................957 Specifications..........................................................................957 CONVERSIONS.................................................................................959 Decimal And Millimeter Equivalent Chart.................................................959 U.S. To Metric Conversion Chart.........................................................959 SERVICE TOOLS REQUIRED......................................................................961 Remote Start Tools......................................................................961 Hydraulic Tools.........................................................................962 Mainframe And Drive Tools...............................................................963 Electrical Tools........................................................................965 HVAC Tools..............................................................................971 ALPHABETICAL INDEX..............................................................................973
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