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Bobcat T595 Compact Track Loader Service Manual SN B3NK11001 & Above – PDF DOWNLOAD
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Bobcat T595 Compact Track Loader Service Manual SN B3NK11001 & Above – PDF DOWNLOAD
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Description
Bobcat T595 Compact Track Loader Service Manual SN B3NK11001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat T595 Compact Track Loader Service Manual SN B3NK11001 & Above – PDF DOWNLOAD
Language : English
Pages : 1144
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T595 Compact Track Loader Service Manual SN B3NK11001 & Above – PDF DOWNLOAD
FOREWORD:
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS / FOPS (Including side screens) is in good condition and is not modified.
2. Check that ROPS mounting hardware is tightened and is Bobcat approved.
3. The seat belt must be correctly installed, functional and in good condition.
4. The seat bar must be correctly adjusted, clean and lubricated.
5. Check lift arm support device, replace if damaged.
6. Machine signs (decals) must be legible and in the correct location.
7. Steering levers, hand controls and foot pedals must return to neutral (as applicable).
8. Check for correct function of the work lights.
9. The parking brake must function correctly.
10. Enclosure door latches must open and close freely.
11. Bob-Tach® attachment mounting system wedges and linkages must function correctly and be in good condition.
12. Safety treads must be in good condition.
13. Check for correct function of indicator lamps.
14. Check all machine fluid levels.
15. Inspect for fuel, oil or hydraulic fluid leaks.
SAFETY INSTRUCTIONS:
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
• The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
• The AEM Safety Manual delivered with the machine gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
TABLE OF CONTENTS:
Bobcat T595 Compact Track Loader Service Manual SN B3NK11001 & 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......................................................................................... 28 Lowering........................................................................................ 29 Cab Door Sensor................................................................................. 30 Special Applications Kit........................................................................ 31 Special Applications Kit Inspection And Maintenance............................................. 31 Forestry Door And Window Kit.................................................................... 32 Forestry Door And Window Kit Inspection And Maintenance......................................... 32 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................................................................ 74 BOB-TACH (HAND LEVER)............................................................................... 75 Inspection And Maintenance...................................................................... 75 BOB-TACH (POWER).................................................................................... 77 Inspection And Maintenance...................................................................... 77 LUBRICATING THE LOADER.............................................................................. 79 Lubrication Locations........................................................................... 79 Track Roller And Idler Lubrication.............................................................. 82 PIVOT PINS.......................................................................................... 83 Inspection And Maintenance...................................................................... 83 LOADER STORAGE AND RETURN TO SERVICE................................................................ 85 Storage......................................................................................... 85 Return To Service............................................................................... 85 STOPPING THE ENGINE AND LEAVING THE LOADER.......................................................... 87 Procedure....................................................................................... 87 EMERGENCY EXIT...................................................................................... 89 Rear Window Identification...................................................................... 89 Rear Window Removal (Latches)................................................................... 89 Rear Window Removal (Rubber Cord)............................................................... 89 External Access (Rear Window With Latches)...................................................... 90 External Access (Rear Window With Rubber Cord).................................................. 90 Front Door...................................................................................... 90 SEAT BELT........................................................................................... 93 Inspection And Maintenance...................................................................... 93 HYDRAULIC SYSTEM........................................................................................ 95 HYDRAULIC / HYDROSTATIC SCHEMATICS.................................................................. 101 HYDRAULIC SYSTEM INFORMATION........................................................................ 113 Glossary Of Hydraulic / Hydrostatic Symbols..................................................... 113 Troubleshooting................................................................................. 117 CYLINDER (LIFT)..................................................................................... 119 Testing......................................................................................... 119 Removal And Installation........................................................................ 120 Parts Identification............................................................................ 124 Disassembly..................................................................................... 125 Assembly........................................................................................ 127 CYLINDER (TILT)..................................................................................... 131 Testing......................................................................................... 131 Removal And Installation........................................................................ 132 Base End Pivot Pin Removal And Installation..................................................... 133 Parts Identification............................................................................ 134 Disassembly..................................................................................... 135 Assembly........................................................................................ 137 CYLINDER (BOB-TACH)................................................................................. 141 Testing......................................................................................... 141 Removal And Installation........................................................................ 142 Parts Identification............................................................................ 143 Disassembly..................................................................................... 144 Assembly........................................................................................ 146 MAIN RELIEF VALVE................................................................................... 149 Description..................................................................................... 149 Testing......................................................................................... 150 Adjusting....................................................................................... 152 Removal And Installation........................................................................ 153 HYDRAULIC CONTROL VALVE (STANDARD).................................................................. 155 Description..................................................................................... 155 Removal And Installation........................................................................ 156 Mount Bracket Removal And Installation.......................................................... 159 Identification Chart............................................................................ 160 Lift Load Check Valve Removal And Installation.................................................. 161 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 162 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 163 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 163 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 164 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 164 Port Relief Valve Removal And Installation...................................................... 165 Plug Removal And Installation................................................................... 167 Rubber Boot Removal And Installation............................................................ 168 End Cap Block Removal And Installation.......................................................... 168 Lift Spool And Detent Removal And Installation.................................................. 169 Tilt Spool Removal And Installation............................................................. 177 Auxiliary Spool Removal And Installation........................................................ 179 Auxiliary Solenoid Removal And Installation..................................................... 180 Solenoid Removal And Installation............................................................... 181 Lock Valve Removal And Installation............................................................. 182 Lift Arm Bypass Orifice Removal And Installation................................................ 184 Main Relief Valve Removal And Installation...................................................... 184 Check Valve Removal And Installation............................................................ 185 HYDRAULIC CONTROL VALVE (ACS) OR (SJC).............................................................. 187 Description..................................................................................... 187 Removal And Installation........................................................................ 187 Actuator Removal And Installation (In Loader)................................................... 191 Actuator Removal And Installation (Out Of Loader)............................................... 193 Identification Chart............................................................................ 196 Mount Bracket Removal And Installation.......................................................... 197 Lift Load Check Valve Removal And Installation.................................................. 197 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 198 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 199 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 199 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 200 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 200 Port Relief Valve Removal And Installation...................................................... 201 Plug Removal And Installation................................................................... 203 End Cap Block Removal And Installation.......................................................... 204 Lift Spool Removal And Installation............................................................. 204 Lift Spool Disassembly And Assembly............................................................. 206 Tilt Spool Removal And Installation............................................................. 207 Auxiliary Spool Removal And Installation........................................................ 209 Auxiliary Solenoid Removal And Installation..................................................... 210 Solenoid Removal And Installation............................................................... 211 Lock Valve Removal And Installation............................................................. 212 Lift Arm Bypass Orifice Removal And Installation................................................ 214 Main Relief Valve Removal And Installation...................................................... 214 Check Valve Removal And Installation............................................................ 215 LIFT ARM BYPASS CONTROL VALVE....................................................................... 217 Description..................................................................................... 217 Testing......................................................................................... 217 Removal And Installation........................................................................ 218 Bracket Removal And Installation................................................................ 219 Disassembly And Assembly........................................................................ 219 HYDRAULIC PUMP...................................................................................... 221 Description..................................................................................... 221 Pump Test At Quick Couplers..................................................................... 222 Direct Pump Test (Standard Section)............................................................. 224 Direct Pump Test (Charge Section)............................................................... 226 Removal And Installation........................................................................ 228 Hydraulic Pump Startup.......................................................................... 230 Parts Identification............................................................................ 231 Disassembly And Assembly........................................................................ 232 HYDRAULIC PUMP (HIGH FLOW).......................................................................... 233 Description..................................................................................... 233 Pump Test At Quick Couplers..................................................................... 234 Direct Pump Test (Standard Section)............................................................. 236 Direct Pump Test (Charge Section)............................................................... 237 Direct Pump Test (High Flow Section)............................................................ 239 High Flow Relief Valve Adjustment............................................................... 241 High Flow Relief Valve Removal And Installation................................................. 242 Solenoid Removal And Installation............................................................... 243 Removal And Installation........................................................................ 244 Hydraulic Pump Startup.......................................................................... 246 Parts Identification............................................................................ 247 Disassembly And Assembly........................................................................ 248 HYDRAULIC / HYDROSTATIC FILTERS..................................................................... 249 Description..................................................................................... 249 Housing Removal And Installation................................................................ 249 HYDRAULIC FLUID RESERVOIR........................................................................... 251 Description..................................................................................... 251 Removal And Installation........................................................................ 251 Hydraulic Fluid Screen.......................................................................... 252 OIL COOLER.......................................................................................... 253 Description..................................................................................... 253 Removal And Installation........................................................................ 253 BUCKET POSITION VALVE............................................................................... 255 Description..................................................................................... 255 Solenoid Removal And Installation............................................................... 255 Solenoid Testing................................................................................ 257 Removal And Installation........................................................................ 257 Disassembly And Assembly........................................................................ 259 REAR AUXILIARY DIVERTER VALVE....................................................................... 261 Description..................................................................................... 261 Solenoid Testing................................................................................ 261 Removal And Installation........................................................................ 262 Disassembly And Assembly........................................................................ 263 BOB-TACH (POWER) BLOCK.............................................................................. 269 Description..................................................................................... 269 Testing Relief Valve............................................................................ 270 Removal And Installation........................................................................ 272 Disassembly And Assembly........................................................................ 274 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK............................................................. 279 Description..................................................................................... 279 Removal And Installation........................................................................ 280 Disassembly And Assembly (FFI/FI)............................................................... 280 Disassembly And Assembly (FFH/FH)............................................................... 282 AUTOMATIC RIDE CONTROL.............................................................................. 285 Description..................................................................................... 285 Removal And Installation........................................................................ 286 Checking The Pressure In The Accumulator........................................................ 289 Adding Nitrogen To The Accumulator.............................................................. 291 HYDROSTATIC SYSTEM...................................................................................... 293 HYDROSTATIC SYSTEM INFORMATION...................................................................... 295 Description..................................................................................... 295 Troubleshooting................................................................................. 296 HYDROSTATIC DRIVE MOTOR............................................................................. 297 Description..................................................................................... 297 Removing And Replacing Fluid.................................................................... 298 Removal And Installation........................................................................ 299 Parts Identification (MCR5T).................................................................... 301 Parts Identification (MCR6T) (Two-Speed)........................................................ 302 Disassembly And Assembly........................................................................ 303 CHARGE PRESSURE..................................................................................... 313 Description..................................................................................... 313 Testing......................................................................................... 314 Adjusting....................................................................................... 316 Sender Removal And Installation................................................................. 318 HYDROSTATIC PUMP.................................................................................... 319 Description..................................................................................... 319 Removal And Installation........................................................................ 320 Hydrostatic Pump Startup........................................................................ 321 Replenishing / High Pressure Relief Valve Removal And Installation.............................. 322 Parts Identification (Left Half)................................................................ 323 Parts Identification (Right Half)............................................................... 324 Disassembly..................................................................................... 325 Assembly........................................................................................ 332 HYDROSTATIC PUMP (SJC).............................................................................. 339 Description..................................................................................... 339 Hydraulic Controller Removal And Installation................................................... 340 Removal And Installation........................................................................ 342 Hydrostatic Pump Startup........................................................................ 344 Parts Identification............................................................................ 345 High Pressure Relief And Bypass Valve........................................................... 346 Charge Relief Valve............................................................................. 347 Disassembly And Assembly........................................................................ 348 Mechanical Neutral Adjustment................................................................... 361 Hydraulic Controller Neutral Adjustment......................................................... 364 HYDROSTATIC PUMP (SJC) (S/N B3NK17848 & ABOVE)...................................................... 367 Description..................................................................................... 367 Port Locations And Gauge Installation........................................................... 368 Removal And Installation........................................................................ 369 Hydrostatic Pump Startup........................................................................ 371 Parts Identification............................................................................ 372 High Pressure Relief And Bypass Valve........................................................... 375 Charge Pressure Relief Valve.................................................................... 376 Disassembly And Assembly........................................................................ 377 Mechanical Neutral Adjustment................................................................... 389 Hydraulic Controller Neutral Adjustment......................................................... 391 DRIVE BELT.......................................................................................... 393 Belt Adjustment................................................................................. 393 Stop Adjustment................................................................................. 393 Belt Replacement................................................................................ 394 Tensioner Pulley Removal And Installation (Earlier Models)...................................... 396 Tensioner Pulley Disassembly And Assembly....................................................... 396 Tensioner Pulley Removal And Installation (Later Models)........................................ 397 Tensioner Pulley Disassembly And Assembly....................................................... 397 TWO-SPEED / BRAKE VALVE............................................................................. 399 Description..................................................................................... 399 Valve Block Removal And Installation............................................................ 400 Valve Block Disassembly And Assembly............................................................ 402 DRAIN MANIFOLD...................................................................................... 405 Description..................................................................................... 405 Drain Manifold Removal And Installation......................................................... 405 DRIVE SYSTEM............................................................................................ 407 BRAKE............................................................................................... 409 Description..................................................................................... 409 Block Removal And Installation.................................................................. 409 Block Disassembly And Assembly.................................................................. 411 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED)...................................................... 413 Description..................................................................................... 413 Checking (Solid-Mounted Undercarriage).......................................................... 415 Adjusting (Solid-Mounted Undercarriage) (Earlier Models With Two Track Tension Fittings)........ 416 Adjusting (Solid-Mounted Undercarriage) (Later Models With One Track Tension Fitting)........... 418 Track Removal And Installation.................................................................. 420 Idler (Front) Removal And Installation.......................................................... 423 Track Tensioner Removal And Installation........................................................ 424 Track Tensioner Disassembly And Assembly........................................................ 425 Idler (Rear) Removal And Installation........................................................... 427 Roller Removal And Installation................................................................. 427 Sprocket Removal And Installation............................................................... 428 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION).................................................. 429 Description..................................................................................... 429 Checking (Roller Suspension Undercarriage)...................................................... 431 Adjusting (Roller Suspension Undercarriage) (Earlier Models With Two Track Tension Fittings).... 432 Adjusting (Roller Suspension Undercarriage) (Earlier Models With Two Track Tension Fittings).... 433 Adjusting (Roller Suspension Undercarriage) (Later Models With One Track Tension Fitting)....... 434 Track Removal And Installation.................................................................. 435 Idler (Front) Removal And Installation.......................................................... 438 Track Tensioner Removal And Installation........................................................ 439 Track Tensioner Disassembly And Assembly........................................................ 440 Idler (Rear) Removal And Installation........................................................... 442 Roller Removal And Installation................................................................. 442 Leaf Spring Removal And Installation............................................................ 443 Sprocket Removal And Installation............................................................... 444 TRACK MAINTENANCE................................................................................... 445 Track Damage Identification..................................................................... 445 MAINFRAME............................................................................................... 457 SEAT BAR............................................................................................ 461 Description..................................................................................... 461 Removal And Installation........................................................................ 461 Disassembly And Assembly........................................................................ 462 Compression Spring Disassembly And Assembly..................................................... 463 OPERATOR CAB........................................................................................ 465 Gas Spring Removal And Installation............................................................. 465 Gas Spring Bracket Disassembly And Assembly..................................................... 466 Removal And Installation........................................................................ 466 OPERATOR SEAT (SUSPENSION).......................................................................... 469 Removal And Installation........................................................................ 469 Slide Rail Removal And Installation............................................................. 469 Seat Belt Removal And Installation.............................................................. 470 Lower Cushion Removal........................................................................... 470 Lower Cushion Installation...................................................................... 471 Back Cushion Removal And Installation........................................................... 471 Shock Removal And Installation.................................................................. 472 3-Point Seat Belt Removal And Installation...................................................... 472 BOB-TACH (HAND LEVER)............................................................................... 475 Description..................................................................................... 475 Removal And Installation........................................................................ 475 Lever And Wedge Disassembly And Assembly........................................................ 477 Pivot Pin Bushing And Seal Removal And Installation............................................. 479 BOB-TACH (POWER).................................................................................... 481 Description..................................................................................... 481 Removal And Installation........................................................................ 481 Lever And Wedge Disassembly And Assembly........................................................ 484 Pivot Pin Bushing And Seal Removal And Installation............................................. 486 LIFT ARMS........................................................................................... 487 Stabilizer Bar Removal And Installation......................................................... 487 Link Removal And Installation................................................................... 488 Removal And Installation........................................................................ 489 REAR GRILLE......................................................................................... 493 Removing........................................................................................ 493 Installing...................................................................................... 493 Shield Removal And Installation................................................................. 494 REAR DOOR (TAILGATE)................................................................................ 495 Removal And Installation........................................................................ 495 Striker Removal And Installation................................................................ 496 Striker Disassembly And Assembly................................................................ 496 Striker (Adjusting)............................................................................. 497 Latch Removal And Installation.................................................................. 498 FUEL TANK........................................................................................... 499 Removal And Installation........................................................................ 499 Fuel Level Sender Removal And Installation...................................................... 501 Fuel Fill Screen Removal And Installation....................................................... 501 CONTROL PEDALS AND LINKAGES......................................................................... 503 Description..................................................................................... 503 Pedal Removal And Installation.................................................................. 503 Linkage Removal And Installation................................................................ 504 Pedal (Adjusting)............................................................................... 505 Floor Pan Removal And Installation.............................................................. 506 CONTROL PEDALS AND LINKAGES (ACS)................................................................... 507 Description..................................................................................... 507 Pedal Removal And Installation.................................................................. 507 Linkage Removal And Installation................................................................ 508 Pedal (Adjusting)............................................................................... 508 Floor Pan Removal And Installation.............................................................. 509 CONTROL PANEL....................................................................................... 511 Description..................................................................................... 511 Removal And Installation........................................................................ 512 Disassembly And Assembly........................................................................ 513 Linkage Removal And Installation................................................................ 518 Pintle Arm Disassembly And Assembly............................................................. 521 Linkage Neutral (Adjusting)..................................................................... 522 Linkage Travel (Adjusting)...................................................................... 526 Shock Removal And Installation.................................................................. 530 CONTROL PANEL (SJC)................................................................................. 531 Description..................................................................................... 531 Removal And Installation........................................................................ 531 CONTROL HANDLE / LEVER.............................................................................. 533 Description..................................................................................... 533 Lever Removal And Installation.................................................................. 533 Boot Removal And Installation................................................................... 534 CONTROL HANDLE / LEVER (ACS)........................................................................ 535 Description..................................................................................... 535 Handle Sensor Removal And Installation.......................................................... 535 Handle Removal And Installation................................................................. 538 Handle Disassembly And Assembly................................................................. 539 Lever Removal And Installation.................................................................. 539 Boot Removal And Installation................................................................... 540 CONTROL HANDLE / LEVER (SJC)........................................................................ 541 Description..................................................................................... 541 Joystick Testing................................................................................ 541 Joystick Removal And Installation............................................................... 542 ACCESS PANEL (INSIDE)............................................................................... 543 Removal And Installation (Left)................................................................. 543 Removal And Installation (Right)................................................................ 543 ACCESS PANEL (INSIDE) (SJC)......................................................................... 545 Removal And Installation (Left)................................................................. 545 Removal And Installation (Right)................................................................ 545 WINDOW (REAR)....................................................................................... 547 Rear Window Identification...................................................................... 547 Removal And Installation (Latches).............................................................. 547 Disassembly And Assembly (Latches).............................................................. 548 Removal (Rubber Cord)........................................................................... 549 Installation (Rubber Cord)...................................................................... 550 WINDOW (TOP)........................................................................................ 553 Removal And Installation........................................................................ 553 WINDOW (SIDE)....................................................................................... 555 Removal And Installation........................................................................ 555 CAB DOOR............................................................................................ 557 Description..................................................................................... 557 Removal And Installation........................................................................ 557 Disassembly And Assembly........................................................................ 558 Aligning........................................................................................ 559 Adjusting....................................................................................... 560 Checking Operation.............................................................................. 560 ARMREST............................................................................................. 561 Description..................................................................................... 561 Removal And Installation........................................................................ 562 Disassembly And Assembly........................................................................ 563 LEFT SIDE LOWER PANEL............................................................................... 565 Removal And Installation........................................................................ 565 Disassembly And Assembly........................................................................ 568 RIGHT SIDE LOWER PANEL.............................................................................. 569 Removal And Installation........................................................................ 569 Disassembly And Assembly........................................................................ 570 HEADLINER........................................................................................... 573 Removal And Installation........................................................................ 573 FAN DUCT PANELS..................................................................................... 575 Removal And Installation........................................................................ 575 ELECTRICAL SYSTEM....................................................................................... 577 ELECTRICAL SCHEMATICS............................................................................... 583 ELECTRICAL SYSTEM INFORMATION....................................................................... 725 Glossary Of Electrical Symbols.................................................................. 725 Standard Cab Harness Connectors................................................................. 728 Deluxe Cab Harness Connectors................................................................... 729 Mainframe Harness Connectors - Manual Controls.................................................. 730 Mainframe Harness Connectors - SJC.............................................................. 731 Description..................................................................................... 732 Troubleshooting................................................................................. 733 Fuse And Relay Location / Identification........................................................ 734 Solenoid Testing................................................................................ 737 BATTERY............................................................................................. 739 Removal And Installation........................................................................ 739 Battery Maintenance............................................................................. 740 Maintaining Battery Charge Level................................................................ 740 Battery Service During Machine Storage.......................................................... 740 Battery Testing................................................................................. 741 Battery Charging................................................................................ 741 Using A Booster Battery (Jump Starting)......................................................... 742 ALTERNATOR.......................................................................................... 743 Belt Adjustment................................................................................. 743 Belt Replacement................................................................................ 743 Charging System Inspection...................................................................... 744 Alternator Voltage Testing...................................................................... 745 Low Voltage Testing............................................................................. 745 High Voltage Testing............................................................................ 746 Removal And Installation........................................................................ 747 Parts Identification............................................................................ 749 STARTER............................................................................................. 751 Testing......................................................................................... 751 Removal And Installation........................................................................ 751 Parts Identification............................................................................ 752 INSTRUMENT PANELS................................................................................... 753 Left Panel...................................................................................... 753 Display Screen.................................................................................. 755 Right Panel (Standard Key Panel)................................................................ 756 Right Panel (Keyless Start Panel)............................................................... 757 Right Panel (Deluxe Instrumentation Panel)...................................................... 758 Left Switch Panel............................................................................... 760 Right Switch Panel.............................................................................. 760 Left Side Lower Panel........................................................................... 761 Right Side Lower Panel.......................................................................... 761 Left Panel Removal And Installation............................................................. 762 Right Panel (Standard Key Panel) Removal And Installation....................................... 762 Right Panel (Keyless Start Panel) Removal And Installation...................................... 763 Right Panel (Deluxe Instrumentation Panel) Removal And Installation............................. 763 Key Switch Disassembly And Assembly............................................................. 764 Alarm Disassembly And Assembly.................................................................. 764 Left Switch Panel Removal And Installation...................................................... 765 Right Switch Panel Removal And Installation..................................................... 765 LIGHTS.............................................................................................. 767 Front Removal And Installation.................................................................. 767 Rear Removal And Installation................................................................... 768 Cab Light Removal And Installation.............................................................. 768 BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY).......................................................... 769 Description..................................................................................... 769 Connector Identification........................................................................ 770 Removal And Installation........................................................................ 776 BOBCAT CONTROLLER (ACS)............................................................................. 777 Description..................................................................................... 777 Connector And Wire Identification............................................................... 778 Removal And Installation........................................................................ 779 BOBCAT CONTROLLER (SJC) (DRIVE)..................................................................... 781 Description..................................................................................... 781 Connector Identification........................................................................ 782 Removal And Installation........................................................................ 784 ENGINE CONTROL UNIT (ECU)........................................................................... 785 Description..................................................................................... 785 Cleaning........................................................................................ 786 Removal And Installation........................................................................ 787 DIAGNOSTIC SERVICE CODES............................................................................ 789 Viewing Service Codes........................................................................... 789 Service Codes List.............................................................................. 790 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)............................................................. 799 Description..................................................................................... 799 Inspecting The BICS™ (Engine STOPPED - Key ON).................................................. 800 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)............ 800 Inspecting The Seat Bar Sensor (Engine RUNNING)................................................. 800 Inspecting The Traction Lock And Parking Brake (Engine RUNNING)................................. 800 Inspecting The Lift Arm Bypass Control.......................................................... 800 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)................................ 800 Troubleshooting................................................................................. 801 SEAT BAR SENSOR..................................................................................... 803 Description..................................................................................... 803 Troubleshooting................................................................................. 803 Testing......................................................................................... 804 Removal......................................................................................... 805 Installation.................................................................................... 807 Bobcat Interlock Control System (BICS™) Circuit Test............................................ 808 TRACTION LOCK....................................................................................... 811 Description..................................................................................... 811 Troubleshooting................................................................................. 812 Inspecting...................................................................................... 813 CONTROL SYSTEM (ACS)................................................................................ 815 Description..................................................................................... 815 Troubleshooting................................................................................. 816 Handle Sensor Connector Disassembly And Assembly................................................ 817 Switch Handle Removal........................................................................... 818 Switch Handle Installation...................................................................... 820 Actuator Connector Disassembly And Assembly..................................................... 823 Handle Lock Solenoid Removal And Installation................................................... 824 Handle Lock Solenoid Disassembly And Assembly................................................... 824 Foot Sensor Removal And Installation............................................................ 825 Foot Sensor Disassembly And Assembly............................................................ 826 Foot Sensor Lock Solenoid Removal And Installation.............................................. 826 ELECTRICAL / HYDRAULIC CONTROLS..................................................................... 827 Identification Chart............................................................................ 827 Description..................................................................................... 828 Identification Chart ACD Group 0................................................................ 829 Identification Chart ACD Group 1................................................................ 830 Identification Chart ACD Group 2................................................................ 831 Identification Chart ACD Group 3................................................................ 832 ELECTRICAL / HYDRAULIC CONTROLS (ACS)............................................................... 833 Identification Chart............................................................................ 833 Description..................................................................................... 834 Identification Chart ACD Group 0................................................................ 835 Identification Chart ACD Group 1................................................................ 836 Identification Chart ACD Group 2................................................................ 837 Identification Chart ACD Group 3................................................................ 838 ELECTRICAL / HYDRAULIC CONTROLS (SJC)............................................................... 839 Identification Chart............................................................................ 839 Description..................................................................................... 840 Identification Chart ACD Group 0................................................................ 841 Identification Chart ACD Group 1................................................................ 842 Identification Chart ACD Group 2................................................................ 843 Identification Chart ACD Group 3................................................................ 844 SERVICE PC (LAPTOP COMPUTER)........................................................................ 845 Connecting Remote Start Tool.................................................................... 845 Connecting Remote Start Tool (Service Tool)..................................................... 845 CALIBRATION......................................................................................... 847 Description..................................................................................... 847 Actuator Testing................................................................................ 847 Lift And Tilt Calibration (SJC)................................................................. 850 Hydrostatic Pump Calibration (SJC).............................................................. 852 Lift And Tilt Calibration (ACS)................................................................. 857 STEERING DRIFT COMPENSATION (OPERATOR MODE)......................................................... 859 Description..................................................................................... 859 Operation....................................................................................... 859 STEERING DRIFT COMPENSATION (SERVICE MODE).......................................................... 861 Description..................................................................................... 861 Operation....................................................................................... 861 CONTROL PANEL SETUP................................................................................. 863 Right Panel Setup (Deluxe Instrumentation Panel)................................................ 863 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....................................................... 867 Password Description............................................................................ 867 Changing The Owner Password..................................................................... 867 Changing The User Passwords..................................................................... 868 Password Lockout Feature........................................................................ 868 PASSWORD SETUP (KEYLESS START PANEL)................................................................ 869 Password Description............................................................................ 869 Changing The Owner Password..................................................................... 869 Password Lockout Feature........................................................................ 869 MAINTENANCE CLOCK................................................................................... 871 Description..................................................................................... 871 Setup........................................................................................... 872 Reset........................................................................................... 875 BACK-UP ALARM SYSTEM................................................................................ 877 Description..................................................................................... 877 Inspecting...................................................................................... 877 Adjusting Switch Position....................................................................... 878 Troubleshooting (Standard And ACS).............................................................. 879 Troubleshooting (Joystick)...................................................................... 880 Alarm Removal And Installation.................................................................. 881 Switch Removal And Installation................................................................. 881 FRONT HORN.......................................................................................... 883 Removal And Installation........................................................................ 883 Troubleshooting................................................................................. 884 Troubleshooting (Joystick)...................................................................... 885 ENGINE SPEED CONTROL (HAND)......................................................................... 887 Removal And Installation........................................................................ 887 ENGINE SPEED CONTROL (FOOT)......................................................................... 889 Removal And Installation........................................................................ 889 Disassembly And Assembly........................................................................ 890 Foot Throttle Calibration....................................................................... 892 CAMSHAFT AND CRANKSHAFT POSITION SENSOR............................................................. 895 Removal And Installation........................................................................ 895 TELEMATICS.......................................................................................... 897 Description..................................................................................... 897 Removal And Installation........................................................................ 897 Procedure....................................................................................... 898 ENGINE SERVICE.......................................................................................... 899 ENGINE INFORMATION.................................................................................. 903 Description..................................................................................... 903 Specifications.................................................................................. 904 Sensor Location................................................................................. 906 Torque Values................................................................................... 912 Troubleshooting................................................................................. 914 Engine Removal And Installation................................................................. 916 Engine Mount Replacement........................................................................ 926 Compression - Testing........................................................................... 928 Injector Signal - Testing....................................................................... 930 Injector Signal - Testing (In-Line)............................................................. 932 Oil Pressure Testing (At Oil Sensor On Block)................................................... 934 Oil Pressure Testing (At Turbocharger Oil Inlet)................................................ 936 DIESEL OXIDATION CATALYST (DOC)..................................................................... 939 Removal And Installation........................................................................ 939 AIR CLEANER......................................................................................... 941 Housing Removal And Installation................................................................ 941 ENGINE COOLING SYSTEM............................................................................... 943 Radiator / Oil Cooler Removal And Installation.................................................. 943 Hydraulic Fan Description....................................................................... 946 Reversible Hydraulic Fan Description............................................................ 946 Fan Duct Removal And Installation............................................................... 946 Hydraulic Fan Motor Assembly Removal And Installation........................................... 947 Hydraulic Fan Motor Removal And Installation.................................................... 948 Hydraulic Fan Motor Disassembly And Assembly.................................................... 950 Blower Housing Removal And Installation......................................................... 958 Water Pump Removal And Installation............................................................. 959 Thermostat Housing Removal And Installation..................................................... 960 Testing The Thermostat.......................................................................... 961 LUBRICATION SYSTEM.................................................................................. 963 Description..................................................................................... 963 Oil Pan Removal And Installation................................................................ 964 Oil Pump Removal And Installation............................................................... 965 Oil Pump Relief Valve Description............................................................... 966 Oil Pump Relief Valve Removal And Installation.................................................. 966 Oil Cooler Removal And Installation............................................................. 967 Oil Filter Head Removal And Installation........................................................ 968 Oil Cooler Bypass Description................................................................... 969 Oil Cooler Bypass Removal And Installation...................................................... 969 FUEL SYSTEM......................................................................................... 971 Description..................................................................................... 971 Transfer Pump / High Pressure Pump Removal And Installation..................................... 972 Fuel Temperature Sensor Removal And Installation................................................ 974 Fuel Cooler Removal And Installation............................................................ 975 Fuel Bypass Valve Removal And Installation...................................................... 975 Fuel Recirculation Valve Removal And Installation............................................... 976 Fuel Rail Assembly Removal And Installation..................................................... 977 Fuel Injector Removal And Installation.......................................................... 978 Injector Coding................................................................................. 980 Removing Air From The Fuel System............................................................... 982 CYLINDER HEAD....................................................................................... 985 Glow Plugs Testing.............................................................................. 985 Glow Plug Removal And Installation.............................................................. 986 Valve Clearance Adjustment...................................................................... 987 Cylinder Head Removal And Installation.......................................................... 989 Cylinder Head Disassembly And Assembly.......................................................... 994 Cylinder Head Inspection........................................................................ 995 Cylinder Head Top Clearance..................................................................... 996 Valve Step Height............................................................................... 997 Valve Stem Height............................................................................... 997 Valve Guide..................................................................................... 998 Valve........................................................................................... 998 Valve Spring.................................................................................... 999 Rocker Arm Shaft Disassembly And Assembly.......................................................1000 Rocker Arm Shaft Inspection.....................................................................1001 Push Rod Inspection.............................................................................1001 CRANKSHAFT AND PISTONS..............................................................................1003 Piston And Connecting Rod Removal And Installation..............................................1003 Piston And Connecting Rod Inspection............................................................1004 Crankshaft Removal And Installation.............................................................1006 Cylinder Block Inspection.......................................................................1009 Crankshaft Inspection...........................................................................1011 Connecting Rod Inspection.......................................................................1011 Engine Component Class..........................................................................1012 CAMSHAFT............................................................................................1015 Removal And Installation........................................................................1015 Inspecting......................................................................................1016 GEARCASE............................................................................................1019 Gearcase Cover Removal And Installation.........................................................1019 Gear Backlash...................................................................................1020 Gear Timing.....................................................................................1021 Idle Gear Removal And Installation..............................................................1022 Idle Gear Inspection............................................................................1022 TURBOCHARGER........................................................................................1023 Description.....................................................................................1023 Removal And Installation........................................................................1023 Inspection......................................................................................1025 FLYWHEEL AND HOUSING................................................................................1027 Flywheel Removal And Installation...............................................................1027 Ring Gear Removal And Installation..............................................................1029 Housing Removal And Installation................................................................1029 EXHAUST GAS RECIRCULATION (EGR) SYSTEM..............................................................1031 Description.....................................................................................1031 Removal And Installation........................................................................1032 Disassembly And Assembly........................................................................1036 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................1039 AIR CONDITIONING SYSTEM FLOW........................................................................1041 Description.....................................................................................1041 Chart...........................................................................................1042 Components......................................................................................1043 Safety Equipment................................................................................1046 REGULAR MAINTENANCE.................................................................................1047 Filters.........................................................................................1047 Belt Adjustment.................................................................................1048 Belt Replacement................................................................................1048 Air Conditioning Condenser......................................................................1048 Air Conditioning Lubrication....................................................................1048 Air Conditioning Service Chart..................................................................1049 Evaporator / Heater Coil........................................................................1050 TROUBLESHOOTING.....................................................................................1053 Blower Motor Does Not Operate...................................................................1053 Blower Motor Operates Normally, But Air Flow Is Insufficient....................................1053 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal......................1053 The Compressor Does Not Operate At All, Or Operates Improperly..................................1053 Gauge Pressure Related Troubleshooting..........................................................1054 Troubleshooting Tree............................................................................1056 Temperature / Pressure Chart....................................................................1060 Poor A/C Performance............................................................................1062 HVAC Repair And Leaks...........................................................................1063 Electrical System...............................................................................1064 Engine Coolant Bypassing The Heater Valve.......................................................1070 Heater Valve Not Opening Or Closing.............................................................1071 SYSTEM CHARGING AND RECLAMATION.....................................................................1073 Refrigerant Identification......................................................................1073 Reclamation And Charging With Recovery / Charging Unit..........................................1074 COMPRESSOR..........................................................................................1077 Removal And Installation........................................................................1077 Oil.............................................................................................1079 Oil Check.......................................................................................1080 CONDENSER...........................................................................................1083 Removal And Installation........................................................................1083 RECEIVER / DRIER....................................................................................1085 Receiver / Drier Removal And Installation.......................................................1085 Pressure Switch Removal And Installation........................................................1087 Schrader® Valve Removal And Installation........................................................1088 EVAPORATOR / HEATER UNIT............................................................................1089 Removal And Installation........................................................................1089 THERMOSTAT..........................................................................................1091 Description.....................................................................................1091 Removal And Installation........................................................................1092 EXPANSION VALVE.....................................................................................1093 Removal And Installation........................................................................1093 EVAPORATOR COIL.....................................................................................1095 Removal And Installation........................................................................1095 HEATER COIL.........................................................................................1097 Removal And Installation........................................................................1097 BLOWER FAN..........................................................................................1099 Removal And Installation........................................................................1099 Disassembly And Assembly........................................................................1099 HEATER VALVE........................................................................................1103 Removal And Installation........................................................................1103 EVAPORATOR / HEATER COVER...........................................................................1105 Removing........................................................................................1105 Installing......................................................................................1105 SPECIFICATIONS..........................................................................................1107 LOADER SPECIFICATIONS...............................................................................1109 Machine Dimensions..............................................................................1109 Performance.....................................................................................1110 Engine..........................................................................................1110 Drive System....................................................................................1111 Controls........................................................................................1111 Hydraulic System................................................................................1112 Electrical System...............................................................................1113 Capacities......................................................................................1113 Tracks..........................................................................................1114 Ground Pressure.................................................................................1114 TECHINCAL SERVICE GUIDE SPECIFICATIONS..............................................................1115 Engine..........................................................................................1115 Engine Torques..................................................................................1115 Cooling System..................................................................................1115 Loader Torques..................................................................................1116 Hydraulic / Hydrostatic System..................................................................1116 Fuel Consumption................................................................................1116 TORQUE SPECIFICATIONS FOR BOLTS.....................................................................1117 Torque For General SAE Bolts....................................................................1117 Torque For General Metric Bolts.................................................................1118 HYDRAULIC CONNECTION SPECIFICATIONS.................................................................1119 Straight Thread O-ring Fitting..................................................................1119 Flare Fitting...................................................................................1120 Tubelines And Hoses.............................................................................1120 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS........................................................1121 Specifications..................................................................................1121 CONVERSIONS.........................................................................................1123 Decimal And Millimeter Equivalent Chart.........................................................1123 U.S. To Metric Conversion Chart.................................................................1123 SERVICE TOOLS REQUIRED..............................................................................1125 Remote Start Tools..............................................................................1125 Hydraulic Tools.................................................................................1126 Mainframe And Drive Tools.......................................................................1129 Electrical Tools................................................................................1132 Engine Tools....................................................................................1133 HVAC Tools......................................................................................1138 ALPHABETICAL INDEX......................................................................................1139
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- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
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S.V
