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Bobcat T550 Compact Track Loader Service Manual SN AJZV11001 & Above – PDF DOWNLOAD
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Bobcat T550 Compact Track Loader Service Manual SN AJZV11001 & Above – PDF DOWNLOAD
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Description
Bobcat T550 Compact Track Loader Service Manual SN AJZV11001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat T550 Compact Track Loader Service Manual SN AJZV11001 & Above – PDF DOWNLOAD
Language : English
Pages : 1294
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T550 Compact Track Loader Service Manual SN AJZV11001 & 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 AJZV11001 & 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..................................................................... 21 Procedure....................................................................................... 21 LIFT ARM SUPPORT DEVICE............................................................................. 23 Description..................................................................................... 23 Installing...................................................................................... 24 Removing........................................................................................ 25 OPERATOR CAB........................................................................................ 27 Description..................................................................................... 27 Raising......................................................................................... 27 Lowering........................................................................................ 28 Cab Door Sensor................................................................................. 29 Special Applications Kit........................................................................ 30 Special Applications Kit Inspection And Maintenance............................................. 30 Forestry Door And Window Kit.................................................................... 31 Forestry Door And Window Kit Inspection And Maintenance......................................... 31 TRANSPORTING THE LOADER ON A TRAILER................................................................ 33 Loading And Unloading........................................................................... 33 Fastening....................................................................................... 33 TOWING THE LOADER................................................................................... 35 Procedure....................................................................................... 35 REMOTE START TOOL KIT - MEL1563..................................................................... 37 Remote Start Tool - MEL1563..................................................................... 37 Service Tool Harness Communicator - MEL1566..................................................... 39 Remote Start Procedure.......................................................................... 39 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666...................................................... 43 Description..................................................................................... 43 Remote Start Tool (Service Tool) - 7022042...................................................... 44 Loader Service Tool Harness - 6689747........................................................... 45 Computer Service Tool Harness - 6689746......................................................... 46 Remote Start Procedure.......................................................................... 47 SERVICE SCHEDULE.................................................................................... 51 Maintenance Intervals........................................................................... 51 ENGINE AIR CLEANER.................................................................................. 53 Replacing Filter Elements....................................................................... 53 ENGINE COOLING SYSTEM............................................................................... 55 Maintenance Platform............................................................................ 55 Cleaning........................................................................................ 55 Checking And Adding Coolant..................................................................... 58 Removing And Replacing Coolant.................................................................. 59 FUEL SYSTEM......................................................................................... 61 Fuel Specifications............................................................................. 61 Biodiesel Blend Fuel............................................................................ 61 Filling The Fuel Tank........................................................................... 62 Fuel Filter..................................................................................... 63 Removing Air From The Fuel System............................................................... 64 ENGINE LUBRICATION SYSTEM........................................................................... 65 Checking And Adding Engine Oil.................................................................. 65 Engine Oil Chart................................................................................ 65 Removing And Replacing Oil And Filter........................................................... 66 HYDRAULIC / HYDROSTATIC SYSTEM...................................................................... 69 Checking And Adding Fluid....................................................................... 69 Hydraulic / Hydrostatic Fluid Chart............................................................. 69 Removing And Replacing Hydraulic Fluid.......................................................... 70 Removing And Replacing Hydraulic / Hydrostatic Filter........................................... 72 Removing And Replacing Hydraulic Charge Filter.................................................. 73 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 Track Roller And Idler Lubrication.............................................................. 83 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)............................................................... 91 External Access (Rear Window With Latches)...................................................... 92 External Access (Rear Window With Rubber Cord).................................................. 92 Front Door...................................................................................... 92 SEAT BELT........................................................................................... 95 Inspection And Maintenance...................................................................... 95 HYDRAULIC SYSTEM........................................................................................ 97 HYDRAULIC / HYDROSTATIC SCHEMATICS.................................................................. 103 HYDRAULIC SYSTEM INFORMATION........................................................................ 123 Glossary Of Hydraulic / Hydrostatic Symbols..................................................... 123 Troubleshooting................................................................................. 127 CYLINDER (LIFT)..................................................................................... 129 Testing......................................................................................... 129 Removal And Installation........................................................................ 130 Parts Identification............................................................................ 133 Disassembly..................................................................................... 134 Assembly........................................................................................ 136 CYLINDER (TILT)..................................................................................... 141 Testing......................................................................................... 141 Removal And Installation........................................................................ 142 Base End Pivot Pin Removal And Installation..................................................... 143 Parts Identification............................................................................ 144 Disassembly..................................................................................... 145 Assembly........................................................................................ 147 CYLINDER (BOB-TACH)................................................................................. 151 Testing......................................................................................... 151 Removal And Installation........................................................................ 152 Parts Identification............................................................................ 153 Disassembly..................................................................................... 154 Assembly........................................................................................ 156 MAIN RELIEF VALVE................................................................................... 159 Description..................................................................................... 159 Testing......................................................................................... 160 Adjusting....................................................................................... 162 Removal And Installation........................................................................ 163 HYDRAULIC CONTROL VALVE (STANDARD).................................................................. 165 Description..................................................................................... 165 Removal And Installation........................................................................ 166 Mount Bracket Removal And Installation.......................................................... 169 Identification Chart............................................................................ 170 Lift Load Check Valve Removal And Installation.................................................. 171 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 172 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 173 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 173 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 174 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 174 Port Relief Valve Removal And Installation...................................................... 175 Plug Removal And Installation................................................................... 177 Rubber Boot Removal And Installation............................................................ 178 End Cap Block Removal And Installation.......................................................... 178 Lift Spool And Detent Removal And Installation.................................................. 179 Tilt Spool Removal And Installation............................................................. 187 Auxiliary Spool Removal And Installation........................................................ 189 Auxiliary Solenoid Removal And Installation..................................................... 190 Solenoid Removal And Installation............................................................... 191 Lock Valve Removal And Installation............................................................. 192 Lift Arm Bypass Orifice Removal And Installation................................................ 194 Main Relief Valve Removal And Installation...................................................... 194 Check Valve Removal And Installation............................................................ 195 HYDRAULIC CONTROL VALVE (ACS) OR (SJC).............................................................. 197 Description..................................................................................... 197 Removal And Installation........................................................................ 197 Actuator Removal And Installation (In Loader)................................................... 202 Actuator Removal And Installation (Out Of Loader)............................................... 204 Identification Chart............................................................................ 207 Mount Bracket Removal And Installation.......................................................... 208 Lift Load Check Valve Removal And Installation.................................................. 208 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 209 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 210 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 210 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 211 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 211 Port Relief Valve Removal And Installation...................................................... 212 Plug Removal And Installation................................................................... 214 End Cap Block Removal And Installation.......................................................... 215 Lift Spool Removal And Installation............................................................. 215 Lift Spool Disassembly And Assembly............................................................. 217 Tilt Spool Removal And Installation............................................................. 218 Auxiliary Spool Removal And Installation........................................................ 220 Auxiliary Solenoid Removal And Installation..................................................... 221 Solenoid Removal And Installation............................................................... 222 Lock Valve Removal And Installation............................................................. 223 Lift Arm Bypass Orifice Removal And Installation................................................ 225 Main Relief Valve Removal And Installation...................................................... 225 Check Valve Removal And Installation............................................................ 226 LIFT ARM BYPASS CONTROL VALVE....................................................................... 227 Description..................................................................................... 227 Testing......................................................................................... 227 Removal And Installation........................................................................ 228 Bracket Removal And Installation................................................................ 229 Disassembly And Assembly........................................................................ 229 HYDRAULIC PUMP...................................................................................... 231 Description..................................................................................... 231 Pump Test At Quick Couplers..................................................................... 232 Direct Pump Test (Standard Section)............................................................. 234 Direct Pump Test (Charge Section)............................................................... 236 Removal And Installation........................................................................ 238 Hydraulic Pump Startup.......................................................................... 240 Parts Identification............................................................................ 241 Disassembly And Assembly........................................................................ 242 HYDRAULIC PUMP (HIGH FLOW).......................................................................... 243 Description..................................................................................... 243 Pump Test At Quick Couplers..................................................................... 244 Direct Pump Test (Standard Section)............................................................. 246 Direct Pump Test (Charge Section)............................................................... 247 Direct Pump Test (High Flow Section)............................................................ 249 High Flow Relief Valve Adjustment............................................................... 251 High Flow Relief Valve Removal And Installation................................................. 252 Solenoid Removal And Installation............................................................... 253 Removal And Installation........................................................................ 254 Hydraulic Pump Startup.......................................................................... 256 Parts Identification............................................................................ 257 Disassembly And Assembly........................................................................ 258 HYDRAULIC / HYDROSTATIC FILTERS..................................................................... 259 Description..................................................................................... 259 Housing Removal And Installation................................................................ 259 HYDRAULIC FLUID RESERVOIR........................................................................... 261 Description..................................................................................... 261 Removal And Installation........................................................................ 261 Hydraulic Fluid Screen.......................................................................... 262 OIL COOLER.......................................................................................... 263 Description..................................................................................... 263 Removal And Installation........................................................................ 263 BUCKET POSITION VALVE............................................................................... 265 Description..................................................................................... 265 Solenoid Removal And Installation............................................................... 265 Solenoid Testing................................................................................ 267 Removal And Installation........................................................................ 267 Disassembly And Assembly........................................................................ 269 REAR AUXILIARY DIVERTER VALVE....................................................................... 271 Description..................................................................................... 271 Solenoid Testing................................................................................ 271 Removal And Installation........................................................................ 272 Disassembly And Assembly........................................................................ 273 BOB-TACH (POWER) BLOCK (S/N AJZV11001 - AJZV14178).................................................. 279 Description..................................................................................... 279 Removal And Installation........................................................................ 279 Disassembly And Assembly........................................................................ 281 BOB-TACH (POWER) BLOCK (S/N AJZV14179 & ABOVE)...................................................... 289 Description..................................................................................... 289 Testing Relief Valve............................................................................ 290 Removal And Installation........................................................................ 292 Disassembly And Assembly........................................................................ 294 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK............................................................. 299 Description..................................................................................... 299 Removal And Installation........................................................................ 300 Disassembly And Assembly (FFI/FI)............................................................... 300 Disassembly And Assembly (FFH/FH)............................................................... 302 AUTOMATIC RIDE CONTROL.............................................................................. 305 Description..................................................................................... 305 Removal And Installation........................................................................ 306 Checking The Pressure In The Accumulator........................................................ 309 Adding Nitrogen To The Accumulator.............................................................. 311 HYDROSTATIC SYSTEM...................................................................................... 313 HYDROSTATIC SYSTEM INFORMATION...................................................................... 315 Description..................................................................................... 315 Troubleshooting................................................................................. 316 HYDROSTATIC DRIVE MOTOR (S/N AJZV11001 - AJZV15133)................................................. 317 Description..................................................................................... 317 Removing And Replacing Fluid.................................................................... 318 Removal And Installation........................................................................ 320 Parts Identification............................................................................ 322 Disassembly..................................................................................... 324 Assembly........................................................................................ 332 HYDROSTATIC DRIVE MOTOR (S/N AJZV15134 & ABOVE)..................................................... 341 Description..................................................................................... 341 Removing And Replacing Fluid.................................................................... 342 Removal And Installation........................................................................ 343 Parts Identification (MCR5T).................................................................... 345 Parts Identification (MCR6T) (Two-Speed)........................................................ 346 Disassembly And Assembly........................................................................ 347 CHARGE PRESSURE..................................................................................... 357 Description..................................................................................... 357 Testing......................................................................................... 358 Adjusting....................................................................................... 359 Sender Removal And Installation (Earlier Models)................................................ 361 Sender Removal And Installation (Later Models).................................................. 361 HYDROSTATIC PUMP.................................................................................... 363 Description..................................................................................... 363 Removal And Installation........................................................................ 364 Hydrostatic Pump Startup........................................................................ 365 Replenishing / High Pressure Relief Valve Removal And Installation.............................. 366 Parts Identification (Left Half)................................................................ 367 Parts Identification (Right Half)............................................................... 368 Disassembly..................................................................................... 369 Assembly........................................................................................ 376 HYDROSTATIC PUMP (SJC).............................................................................. 383 Description..................................................................................... 383 Hydraulic Controller Removal And Installation................................................... 384 Removal And Installation........................................................................ 386 Hydrostatic Pump Startup........................................................................ 388 Parts Identification............................................................................ 389 High Pressure Relief And Bypass Valve........................................................... 390 Charge Relief Valve............................................................................. 391 Disassembly And Assembly........................................................................ 392 Mechanical Neutral Adjustment................................................................... 405 Hydraulic Controller Neutral Adjustment......................................................... 408 HYDROSTATIC PUMP (SJC) (S/N AJZV19671 & ABOVE)...................................................... 411 Description..................................................................................... 411 Port Locations And Gauge Installation........................................................... 412 Removal And Installation........................................................................ 413 Hydrostatic Pump Startup........................................................................ 415 Parts Identification............................................................................ 416 High Pressure Relief And Bypass Valve........................................................... 419 Charge Pressure Relief Valve.................................................................... 420 Disassembly And Assembly........................................................................ 421 Mechanical Neutral Adjustment................................................................... 432 Hydraulic Controller Neutral Adjustment......................................................... 434 DRIVE BELT.......................................................................................... 437 Belt Adjustment................................................................................. 437 Stop Adjustment................................................................................. 437 Belt Replacement................................................................................ 438 Tensioner Pulley Removal And Installation (Earlier Models)...................................... 440 Tensioner Pulley Disassembly And Assembly....................................................... 440 Tensioner Pulley Removal And Installation (Later Models)........................................ 441 Tensioner Pulley Disassembly And Assembly....................................................... 441 TWO-SPEED / BRAKE VALVE............................................................................. 443 Description..................................................................................... 443 Valve Block Removal And Installation............................................................ 444 Valve Block Disassembly And Assembly............................................................ 446 DRAIN MANIFOLD...................................................................................... 449 Description..................................................................................... 449 Drain Manifold Removal And Installation......................................................... 449 DRIVE SYSTEM............................................................................................ 451 BRAKE............................................................................................... 453 Description..................................................................................... 453 Block Removal And Installation.................................................................. 453 Block Disassembly And Assembly.................................................................. 455 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) (S/N AJZV11001 - AJZV13999).......................... 457 Description..................................................................................... 457 Checking Tension................................................................................ 458 Adjusting Tension............................................................................... 459 Track Removal And Installation.................................................................. 460 Idler (Front) Removal And Installation.......................................................... 462 Track Tensioner Disassembly And Assembly........................................................ 465 Idler (Rear) Removal And Installation........................................................... 467 Roller Removal And Installation................................................................. 467 Sprocket Removal And Installation............................................................... 468 Track Housing Removal And Installation.......................................................... 469 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) (S/N AJZV11001 - AJZV13999)...................... 471 Description..................................................................................... 471 Checking Tension................................................................................ 472 Adjusting Tension............................................................................... 473 Track Removal And Installation.................................................................. 475 Idler (Front) Removal And Installation.......................................................... 477 Track Tensioner Disassembly And Assembly........................................................ 480 Idler (Rear) Removal And Installation........................................................... 482 Roller Removal And Installation................................................................. 482 Leaf Spring Removal And Installation............................................................ 483 Sprocket Removal And Installation............................................................... 484 Track Housing Removal And Installation.......................................................... 485 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) (S/N AJZV14001 & ABOVE).............................. 487 Description..................................................................................... 487 Checking (Solid-Mounted Undercarriage).......................................................... 489 Adjusting (Solid-Mounted Undercarriage) (Earlier Models With Two Track Tension Fittings)........ 490 Adjusting (Solid-Mounted Undercarriage) (Later Models With One Track Tension Fitting)........... 492 Track Removal And Installation.................................................................. 493 Idler (Front) Removal And Installation.......................................................... 496 Track Tensioner Removal And Installation........................................................ 497 Track Tensioner Disassembly And Assembly........................................................ 498 Idler (Rear) Removal And Installation........................................................... 500 Roller Removal And Installation................................................................. 500 Sprocket Removal And Installation (Twelve Bolt Sprocket)........................................ 501 Sprocket Removal And Installation (Sixteen Bolt Sprocket)....................................... 501 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) (S/N AJZV14001 & ABOVE).......................... 503 Description..................................................................................... 503 Checking (Roller Suspension Undercarriage)...................................................... 504 Adjusting (Roller Suspension Undercarriage) (Earlier Models With Two Track Tension Fittings).... 505 Adjusting (Roller Suspension Undercarriage) (Later Models With One Track Tension Fitting)....... 507 Track Removal And Installation.................................................................. 508 Idler (Front) Removal And Installation.......................................................... 511 Track Tensioner Removal And Installation........................................................ 512 Track Tensioner Disassembly And Assembly........................................................ 513 Idler (Rear) Removal And Installation........................................................... 515 Roller Removal And Installation................................................................. 515 Leaf Spring Removal And Installation............................................................ 516 Sprocket Removal And Installation (Twelve Bolt Sprocket)........................................ 517 Sprocket Removal And Installation (Sixteen Bolt Sprocket)....................................... 517 TRACK MAINTENANCE................................................................................... 519 Track Damage Identification..................................................................... 519 MAINFRAME............................................................................................... 531 SEAT BAR............................................................................................ 535 Description..................................................................................... 535 Removal And Installation........................................................................ 535 Disassembly And Assembly........................................................................ 536 Compression Spring Disassembly And Assembly..................................................... 537 OPERATOR CAB........................................................................................ 539 Gas Spring Removal And Installation............................................................. 539 Gas Spring Bracket Disassembly And Assembly..................................................... 540 Removal And Installation........................................................................ 540 OPERATOR SEAT (SUSPENSION).......................................................................... 543 Removal And Installation........................................................................ 543 Slide Rail Removal And Installation............................................................. 543 Seat Belt Removal And Installation.............................................................. 544 Lower Cushion Removal........................................................................... 544 Lower Cushion Installation...................................................................... 545 Back Cushion Removal And Installation........................................................... 545 Shock Removal And Installation.................................................................. 546 3-Point Seat Belt Removal And Installation...................................................... 546 BOB-TACH (HAND LEVER)............................................................................... 549 Description..................................................................................... 549 Removal And Installation........................................................................ 549 Lever And Wedge Disassembly And Assembly........................................................ 551 Pivot Pin Bushing And Seal Removal And Installation............................................. 553 BOB-TACH (POWER).................................................................................... 555 Description..................................................................................... 555 Removal And Installation........................................................................ 555 Lever And Wedge Disassembly And Assembly........................................................ 558 Pivot Pin Bushing And Seal Removal And Installation............................................. 560 LIFT ARMS........................................................................................... 561 Removal And Installation........................................................................ 561 REAR GRILLE......................................................................................... 563 Removing........................................................................................ 563 Installing...................................................................................... 563 Shield Removal And Installation................................................................. 564 REAR DOOR (TAILGATE)................................................................................ 565 Removal And Installation........................................................................ 565 Striker Removal And Installation................................................................ 566 Striker Disassembly And Assembly................................................................ 566 Striker (Adjusting)............................................................................. 567 Latch Removal And Installation.................................................................. 568 FUEL TANK........................................................................................... 569 Removal And Installation........................................................................ 569 Fuel Level Sender Removal And Installation...................................................... 571 Fuel Fill Screen Removal And Installation....................................................... 571 CONTROL PEDALS AND LINKAGES......................................................................... 573 Description..................................................................................... 573 Pedal Removal And Installation.................................................................. 573 Linkage Removal And Installation................................................................ 574 Pedal (Adjusting)............................................................................... 575 Floor Pan Removal And Installation.............................................................. 576 CONTROL PEDALS AND LINKAGES (ACS)................................................................... 577 Description..................................................................................... 577 Pedal Removal And Installation.................................................................. 577 Linkage Removal And Installation................................................................ 578 Pedal (Adjusting)............................................................................... 578 Floor Pan Removal And Installation.............................................................. 579 CONTROL PANEL....................................................................................... 581 Description..................................................................................... 581 Removal And Installation........................................................................ 582 Disassembly And Assembly........................................................................ 583 Linkage Removal And Installation................................................................ 588 Pintle Arm Disassembly And Assembly............................................................. 591 Linkage Neutral (Adjusting)..................................................................... 592 Linkage Travel (Adjusting)...................................................................... 596 Shock Removal And Installation.................................................................. 600 CONTROL PANEL (SJC)................................................................................. 601 Description..................................................................................... 601 Removal And Installation........................................................................ 601 CONTROL HANDLE / LEVER.............................................................................. 603 Description..................................................................................... 603 Lever Removal And Installation.................................................................. 603 Boot Removal And Installation................................................................... 604 CONTROL HANDLE / LEVER (ACS)........................................................................ 605 Description..................................................................................... 605 Handle Sensor Removal And Installation.......................................................... 605 Handle Removal And Installation................................................................. 608 Handle Disassembly And Assembly................................................................. 609 Lever Removal And Installation.................................................................. 609 Boot Removal And Installation................................................................... 610 CONTROL HANDLE / LEVER (SJC)........................................................................ 611 Description..................................................................................... 611 Joystick Testing................................................................................ 611 Joystick Removal And Installation............................................................... 612 ACCESS PANEL (INSIDE)............................................................................... 613 Removal And Installation (Left)................................................................. 613 Removal And Installation (Right)................................................................ 613 ACCESS PANEL (INSIDE) (SJC)......................................................................... 615 Removal And Installation (Left)................................................................. 615 Removal And Installation (Right)................................................................ 615 WINDOW (REAR)....................................................................................... 617 Removal And Installation........................................................................ 617 Disassembly And Assembly........................................................................ 617 WINDOW (TOP)........................................................................................ 619 Removal And Installation........................................................................ 619 WINDOW (SIDE)....................................................................................... 621 Removal And Installation........................................................................ 621 CAB DOOR............................................................................................ 623 Description..................................................................................... 623 Removal And Installation........................................................................ 623 Disassembly And Assembly........................................................................ 624 Aligning........................................................................................ 625 Adjusting....................................................................................... 626 Checking Operation.............................................................................. 626 ARMREST............................................................................................. 627 Description..................................................................................... 627 Removal And Installation........................................................................ 628 Disassembly And Assembly........................................................................ 629 LEFT SIDE LOWER PANEL............................................................................... 631 Removal And Installation........................................................................ 631 Disassembly And Assembly........................................................................ 633 RIGHT SIDE LOWER PANEL.............................................................................. 635 Removal And Installation........................................................................ 635 Disassembly And Assembly........................................................................ 636 HEADLINER........................................................................................... 639 Removal And Installation........................................................................ 639 FAN DUCT PANELS..................................................................................... 641 Removal And Installation........................................................................ 641 ELECTRICAL SYSTEM....................................................................................... 643 ELECTRICAL SCHEMATICS............................................................................... 649 ELECTRICAL SYSTEM INFORMATION....................................................................... 859 Glossary Of Electrical Symbols.................................................................. 859 Standard Cab Harness Connectors................................................................. 862 Deluxe Cab Harness Connectors................................................................... 863 Mainframe Harness Connectors - Manual Controls.................................................. 864 Mainframe Harness Connectors - SJC.............................................................. 865 Description..................................................................................... 866 Troubleshooting................................................................................. 867 Fuse And Relay Location / Identification........................................................ 868 Solenoid Testing................................................................................ 873 BATTERY............................................................................................. 875 Removal And Installation........................................................................ 875 Battery Maintenance............................................................................. 876 Maintaining Battery Charge Level................................................................ 876 Battery Service During Machine Storage.......................................................... 876 Battery Testing................................................................................. 877 Battery Charging................................................................................ 877 Using A Booster Battery (Jump Starting)......................................................... 878 ALTERNATOR.......................................................................................... 879 Belt Adjustment................................................................................. 879 Belt Replacement................................................................................ 879 Charging System Inspection...................................................................... 880 Alternator Voltage Testing...................................................................... 881 Low Voltage Testing............................................................................. 881 High Voltage Testing............................................................................ 882 Removal And Installation........................................................................ 883 Parts Identification............................................................................ 885 STARTER............................................................................................. 887 Testing......................................................................................... 887 Removal And Installation........................................................................ 887 Parts Identification............................................................................ 888 INSTRUMENT PANELS................................................................................... 889 Left Panel...................................................................................... 889 Display Screen.................................................................................. 891 Right Panel (Standard Key Panel)................................................................ 892 Right Panel (Keyless Start Panel)............................................................... 893 Right Panel (Deluxe Instrumentation Panel)...................................................... 894 Left Switch Panel............................................................................... 896 Right Switch Panel.............................................................................. 896 Left Side Lower Panel........................................................................... 897 Right Side Lower Panel.......................................................................... 897 Left Panel Removal And Installation............................................................. 898 Right Panel (Standard Key Panel) Removal And Installation....................................... 898 Right Panel (Keyless Start Panel) Removal And Installation...................................... 899 Right Panel (Deluxe Instrumentation Panel) Removal And Installation............................. 899 Key Switch Disassembly And Assembly............................................................. 900 Alarm Disassembly And Assembly.................................................................. 900 Left Switch Panel Removal And Installation...................................................... 901 Right Switch Panel Removal And Installation..................................................... 901 LIGHTS.............................................................................................. 903 Front Removal And Installation.................................................................. 903 Rear Removal And Installation................................................................... 904 Cab Light Removal And Installation (Earlier Models)............................................. 904 Cab Light Removal And Installation (Later Models)............................................... 905 BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY).......................................................... 907 Description..................................................................................... 907 Connector Identification........................................................................ 908 Removal And Installation........................................................................ 914 BOBCAT CONTROLLER (ACS)............................................................................. 915 Description..................................................................................... 915 Connector And Wire Identification............................................................... 916 Removal And Installation........................................................................ 917 BOBCAT CONTROLLER (SJC) (DRIVE)..................................................................... 919 Description..................................................................................... 919 Connector Identification........................................................................ 920 Removal And Installation........................................................................ 922 ENGINE CONTROL UNIT (ECU)........................................................................... 923 Description..................................................................................... 923 Cleaning........................................................................................ 924 Removal And Installation........................................................................ 925 DIAGNOSTIC SERVICE CODES............................................................................ 927 Viewing Service Codes........................................................................... 927 Service Codes List.............................................................................. 928 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)............................................................. 937 Description..................................................................................... 937 Inspecting The BICS™ (Engine STOPPED - Key ON).................................................. 938 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)............ 938 Inspecting The Seat Bar Sensor (Engine RUNNING)................................................. 938 Inspecting The Traction Lock And Parking Brake (Engine RUNNING)................................. 938 Inspecting The Lift Arm Bypass Control.......................................................... 938 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)................................ 938 Troubleshooting................................................................................. 940 SEAT BAR SENSOR..................................................................................... 941 Description..................................................................................... 941 Troubleshooting................................................................................. 942 Testing......................................................................................... 943 Removal......................................................................................... 944 Installation.................................................................................... 946 Bobcat Interlock Control System (BICS™) Circuit Test............................................ 947 TRACTION LOCK....................................................................................... 949 Description..................................................................................... 949 Troubleshooting................................................................................. 950 Inspecting...................................................................................... 951 CONTROL SYSTEM (ACS)................................................................................ 953 Description..................................................................................... 953 Troubleshooting................................................................................. 954 Handle Sensor Connector Disassembly And Assembly................................................ 955 Switch Handle Removal........................................................................... 956 Switch Handle Installation...................................................................... 958 Actuator Connector Disassembly And Assembly..................................................... 961 Handle Lock Solenoid Removal And Installation................................................... 962 Handle Lock Solenoid Disassembly And Assembly................................................... 962 Foot Sensor Removal And Installation............................................................ 963 Foot Sensor Disassembly And Assembly............................................................ 964 Foot Sensor Lock Solenoid Removal And Installation.............................................. 964 ELECTRICAL / HYDRAULIC CONTROLS..................................................................... 965 Identification Chart............................................................................ 965 Description..................................................................................... 966 Identification Chart ACD Group 0................................................................ 967 Identification Chart ACD Group 1................................................................ 968 Identification Chart ACD Group 2................................................................ 969 Identification Chart ACD Group 3................................................................ 970 ELECTRICAL / HYDRAULIC CONTROLS (ACS)............................................................... 971 Identification Chart............................................................................ 971 Description..................................................................................... 972 Identification Chart ACD Group 0................................................................ 973 Identification Chart ACD Group 1................................................................ 974 Identification Chart ACD Group 2................................................................ 975 Identification Chart ACD Group 3................................................................ 976 ELECTRICAL / HYDRAULIC CONTROLS (SJC)............................................................... 977 Identification Chart............................................................................ 977 Description..................................................................................... 978 Identification Chart ACD Group 0................................................................ 979 Identification Chart ACD Group 1................................................................ 980 Identification Chart ACD Group 2................................................................ 981 Identification Chart ACD Group 3................................................................ 982 SERVICE PC (LAPTOP COMPUTER)........................................................................ 983 Connecting Remote Start Tool.................................................................... 983 Connecting Remote Start Tool (Service Tool)..................................................... 983 CALIBRATION......................................................................................... 985 Description..................................................................................... 985 Actuator Testing................................................................................ 985 Lift And Tilt Calibration (SJC)................................................................. 988 Hydrostatic Pump Calibration (SJC).............................................................. 990 Lift And Tilt Calibration (ACS)................................................................. 995 STEERING DRIFT COMPENSATION (OPERATOR MODE)......................................................... 997 Description..................................................................................... 997 Operation....................................................................................... 997 STEERING DRIFT COMPENSATION (SERVICE MODE).......................................................... 999 Description..................................................................................... 999 Operation....................................................................................... 999 CONTROL PANEL SETUP.................................................................................1001 Right Panel Setup (Deluxe Instrumentation Panel)................................................1001 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL).......................................................1005 Password Description............................................................................1005 Changing The Owner Password.....................................................................1005 Changing The User Passwords.....................................................................1006 Password Lockout Feature........................................................................1006 PASSWORD SETUP (KEYLESS START PANEL)................................................................1007 Password Description............................................................................1007 Changing The Owner Password.....................................................................1007 Password Lockout Feature........................................................................1007 MAINTENANCE CLOCK...................................................................................1009 Description.....................................................................................1009 Setup...........................................................................................1010 Reset...........................................................................................1013 BACK-UP ALARM SYSTEM................................................................................1015 Description.....................................................................................1015 Inspecting......................................................................................1015 Adjusting Switch Position.......................................................................1016 Troubleshooting (Standard And ACS)..............................................................1017 Troubleshooting (Joystick)......................................................................1018 Alarm Removal And Installation..................................................................1019 Switch Removal And Installation.................................................................1019 FRONT HORN..........................................................................................1021 Removal And Installation........................................................................1021 Troubleshooting.................................................................................1022 Troubleshooting (Joystick)......................................................................1023 ENGINE SPEED CONTROL (HAND).........................................................................1025 Removal And Installation........................................................................1025 ENGINE SPEED CONTROL (FOOT).........................................................................1027 Removal And Installation........................................................................1027 Disassembly And Assembly........................................................................1028 Foot Throttle Calibration.......................................................................1030 CAMSHAFT AND CRANKSHAFT POSITION SENSOR.............................................................1033 Removal And Installation........................................................................1033 TELEMATICS..........................................................................................1035 Description.....................................................................................1035 Removal And Installation........................................................................1035 Procedure.......................................................................................1036 ENGINE SERVICE..........................................................................................1037 ENGINE INFORMATION..................................................................................1041 Description.....................................................................................1041 Specifications..................................................................................1042 Sensor Location.................................................................................1044 Torque Values...................................................................................1050 Troubleshooting.................................................................................1052 Engine Removal And Installation.................................................................1054 Engine Mount Replacement........................................................................1064 Compression - Testing...........................................................................1066 Injector Signal - Testing.......................................................................1068 Injector Signal - Testing (In-Line).............................................................1070 Oil Pressure Testing (At Oil Sensor On Block)...................................................1072 Oil Pressure Testing (At Turbocharger Oil Inlet)................................................1074 DIESEL OXIDATION CATALYST (DOC).....................................................................1077 Removal And Installation........................................................................1077 AIR CLEANER.........................................................................................1079 Housing Removal And Installation................................................................1079 ENGINE COOLING SYSTEM (EARLIER MODELS)..............................................................1081 Radiator / Oil Cooler Removal And Installation..................................................1081 Hydraulic Fan Description.......................................................................1084 Fan Duct Removal And Installation...............................................................1084 Hydraulic Fan Motor Assembly Removal And Installation...........................................1085 Hydraulic Fan Motor Removal And Installation....................................................1086 Hydraulic Fan Motor Disassembly And Assembly....................................................1088 Blower Housing Removal And Installation.........................................................1089 Water Pump Removal And Installation.............................................................1090 Thermostat Housing Removal And Installation.....................................................1091 Testing The Thermostat..........................................................................1092 ENGINE COOLING SYSTEM (LATER MODELS)................................................................1093 Radiator / Oil Cooler Removal And Installation..................................................1093 Hydraulic Fan Description.......................................................................1096 Reversible Hydraulic Fan Description............................................................1096 Fan Duct Removal And Installation...............................................................1096 Hydraulic Fan Motor Assembly Removal And Installation...........................................1097 Hydraulic Fan Motor Removal And Installation....................................................1098 Hydraulic Fan Motor Disassembly And Assembly....................................................1100 Blower Housing Removal And Installation.........................................................1108 Water Pump Removal And Installation.............................................................1109 Thermostat Housing Removal And Installation.....................................................1110 Testing The Thermostat..........................................................................1111 LUBRICATION SYSTEM..................................................................................1113 Description.....................................................................................1113 Oil Pan Removal And Installation................................................................1114 Oil Pump Removal And Installation...............................................................1115 Oil Pump Relief Valve Description...............................................................1116 Oil Pump Relief Valve Removal And Installation..................................................1116 Oil Cooler Removal And Installation.............................................................1117 Oil Filter Head Removal And Installation........................................................1118 Oil Cooler Bypass Description...................................................................1119 Oil Cooler Bypass Removal And Installation......................................................1119 FUEL SYSTEM.........................................................................................1121 Description.....................................................................................1121 Transfer Pump / High Pressure Pump Removal And Installation.....................................1122 Fuel Temperature Sensor Removal And Installation................................................1124 Fuel Cooler Removal And Installation............................................................1125 Fuel Bypass Valve Removal And Installation......................................................1125 Fuel Recirculation Valve Removal And Installation...............................................1126 Fuel Rail Assembly Removal And Installation.....................................................1127 Fuel Injector Removal And Installation..........................................................1128 Injector Coding.................................................................................1130 Removing Air From The Fuel System...............................................................1132 CYLINDER HEAD.......................................................................................1135 Glow Plugs Testing..............................................................................1135 Glow Plug Removal And Installation..............................................................1136 Valve Clearance Adjustment......................................................................1137 Cylinder Head Removal And Installation..........................................................1139 Cylinder Head Disassembly And Assembly..........................................................1144 Cylinder Head Inspection........................................................................1145 Cylinder Head Top Clearance.....................................................................1146 Valve Step Height...............................................................................1147 Valve Stem Height...............................................................................1147 Valve Guide.....................................................................................1148 Valve...........................................................................................1148 Valve Spring....................................................................................1149 Rocker Arm Shaft Disassembly And Assembly.......................................................1150 Rocker Arm Shaft Inspection.....................................................................1151 Push Rod Inspection.............................................................................1151 CRANKSHAFT AND PISTONS..............................................................................1153 Piston And Connecting Rod Removal And Installation..............................................1153 Piston And Connecting Rod Inspection............................................................1154 Crankshaft Removal And Installation.............................................................1156 Cylinder Block Inspection.......................................................................1159 Crankshaft Inspection...........................................................................1161 Connecting Rod Inspection.......................................................................1161 Engine Component Class..........................................................................1162 CAMSHAFT............................................................................................1165 Removal And Installation........................................................................1165 Inspecting......................................................................................1166 GEARCASE............................................................................................1169 Gearcase Cover Removal And Installation.........................................................1169 Gear Backlash...................................................................................1170 Gear Timing.....................................................................................1171 Idle Gear Removal And Installation..............................................................1172 Idle Gear Inspection............................................................................1172 TURBOCHARGER........................................................................................1173 Description.....................................................................................1173 Removal And Installation........................................................................1173 Inspection......................................................................................1176 FLYWHEEL AND HOUSING................................................................................1177 Flywheel Removal And Installation...............................................................1177 Ring Gear Removal And Installation..............................................................1179 Housing Removal And Installation................................................................1179 EXHAUST GAS RECIRCULATION (EGR) SYSTEM..............................................................1181 Description.....................................................................................1181 Removal And Installation........................................................................1182 Disassembly And Assembly........................................................................1186 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................1189 AIR CONDITIONING SYSTEM FLOW........................................................................1191 Description.....................................................................................1191 Chart...........................................................................................1192 Components......................................................................................1193 Safety Equipment................................................................................1196 REGULAR MAINTENANCE.................................................................................1197 Filters.........................................................................................1197 Belt Adjustment.................................................................................1198 Belt Replacement................................................................................1198 Air Conditioning Condenser......................................................................1198 Air Conditioning Lubrication....................................................................1198 Air Conditioning Service Chart..................................................................1199 Evaporator / Heater Coil........................................................................1200 TROUBLESHOOTING.....................................................................................1203 Blower Motor Does Not Operate...................................................................1203 Blower Motor Operates Normally, But Air Flow Is Insufficient....................................1203 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal......................1203 The Compressor Does Not Operate At All, Or Operates Improperly..................................1203 Gauge Pressure Related Troubleshooting..........................................................1204 Troubleshooting Tree............................................................................1206 Temperature / Pressure Chart....................................................................1210 Poor A/C Performance............................................................................1212 HVAC Repair And Leaks...........................................................................1213 Electrical System...............................................................................1214 Engine Coolant Bypassing The Heater Valve.......................................................1220 Heater Valve Not Opening Or Closing.............................................................1221 SYSTEM CHARGING AND RECLAMATION.....................................................................1223 Refrigerant Identification......................................................................1223 Reclamation And Charging With Recovery / Charging Unit..........................................1224 COMPRESSOR..........................................................................................1227 Removal And Installation........................................................................1227 Oil.............................................................................................1229 Oil Check.......................................................................................1230 CONDENSER...........................................................................................1233 Removal And Installation........................................................................1233 RECEIVER / DRIER....................................................................................1235 Receiver / Drier Removal And Installation.......................................................1235 Pressure Switch Removal And Installation........................................................1237 Schrader® Valve Removal And Installation........................................................1238 EVAPORATOR / HEATER UNIT............................................................................1239 Removal And Installation........................................................................1239 THERMOSTAT..........................................................................................1241 Description.....................................................................................1241 Removal And Installation........................................................................1242 EXPANSION VALVE.....................................................................................1243 Removal And Installation........................................................................1243 EVAPORATOR COIL.....................................................................................1245 Removal And Installation........................................................................1245 HEATER COIL.........................................................................................1247 Removal And Installation........................................................................1247 BLOWER FAN..........................................................................................1249 Removal And Installation........................................................................1249 Disassembly And Assembly........................................................................1249 HEATER VALVE........................................................................................1253 Removal And Installation........................................................................1253 EVAPORATOR / HEATER COVER...........................................................................1255 Removing........................................................................................1255 Installing......................................................................................1255 SPECIFICATIONS..........................................................................................1257 (T550) LOADER SPECIFICATIONS........................................................................1259 Machine Dimensions..............................................................................1259 Performance.....................................................................................1260 Engine..........................................................................................1260 Drive System....................................................................................1261 Controls........................................................................................1261 Hydraulic System................................................................................1262 Electrical System...............................................................................1263 Capacities......................................................................................1263 Tracks..........................................................................................1264 Ground Pressure.................................................................................1264 TECHINCAL SERVICE GUIDE SPECIFICATIONS..............................................................1265 Engine..........................................................................................1265 Engine Torques..................................................................................1265 Cooling System..................................................................................1265 Loader Torques..................................................................................1266 Hydraulic / Hydrostatic System..................................................................1266 Fuel Consumption................................................................................1266 TORQUE SPECIFICATIONS FOR BOLTS.....................................................................1267 Torque For General SAE Bolts....................................................................1267 Torque For General Metric Bolts.................................................................1268 HYDRAULIC CONNECTION SPECIFICATIONS.................................................................1269 Straight Thread O-ring Fitting..................................................................1269 Flare Fitting...................................................................................1270 Tubelines And Hoses.............................................................................1270 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS........................................................1271 Specifications..................................................................................1271 CONVERSIONS.........................................................................................1273 Decimal And Millimeter Equivalent Chart.........................................................1273 U.S. To Metric Conversion Chart.................................................................1273 SERVICE TOOLS REQUIRED..............................................................................1275 Remote Start Tools..............................................................................1275 Hydraulic Tools.................................................................................1276 Mainframe And Drive Tools.......................................................................1279 Electrical Tools................................................................................1282 Engine Tools....................................................................................1283 HVAC Tools......................................................................................1288 ALPHABETICAL INDEX......................................................................................1289
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