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Bobcat T740 Compact Track Loader Service Manual SN B3CA11001 & Above – PDF DOWNLOAD
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Bobcat T740 Compact Track Loader Service Manual SN B3CA11001 & Above – PDF DOWNLOAD
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Description
Bobcat T740 Compact Track Loader Service Manual SN B3CA11001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat T740 Compact Track Loader Service Manual SN B3CA11001 & Above – PDF DOWNLOAD
Language : English
Pages : 1061
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T740 Compact Track Loader Service Manual SN B3CA11001 & 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 T740 Compact Track Loader Service Manual SN B3CA11001 & 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........................................................................................ 126 CYLINDER (TILT)..................................................................................... 131 Testing......................................................................................... 131 Removal And Installation........................................................................ 132 Base End Pivot Pin Removal And Installation..................................................... 134 Parts Identification............................................................................ 135 Disassembly..................................................................................... 136 Assembly........................................................................................ 138 CYLINDER (BOB-TACH)................................................................................. 141 Testing......................................................................................... 141 Removal And Installation........................................................................ 142 Parts Identification............................................................................ 143 Disassembly..................................................................................... 144 Assembly........................................................................................ 145 MAIN RELIEF VALVE................................................................................... 149 Description..................................................................................... 149 Testing......................................................................................... 150 Main Relief Valve Adjustment.................................................................... 152 Main Relief Valve Removal And Installation...................................................... 152 Auxiliary Relief Valve Adjustment............................................................... 153 Auxiliary Relief Valve Removal And Installation................................................. 154 HYDRAULIC CONTROL VALVE (STANDARD).................................................................. 155 Description..................................................................................... 155 Removal And Installation........................................................................ 156 Mount Bracket Removal And Installation.......................................................... 160 Identification Chart............................................................................ 161 Lift Load Check Valve Removal And Installation.................................................. 162 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 163 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 164 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 164 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 165 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 165 Port Relief Valve Removal And Installation...................................................... 166 Plug Removal And Installation................................................................... 168 Rubber Boot Removal And Installation............................................................ 169 End Cap Block Removal And Installation.......................................................... 169 Lift Spool And Detent Removal................................................................... 170 Lift Spool And Detent Disassembly............................................................... 172 Lift Spool And Detent Assembly.................................................................. 174 Lift Spool And Detent Installation.............................................................. 176 Tilt Spool Removal And Installation............................................................. 178 Tilt Spool Disassembly And Assembly............................................................. 179 Auxiliary Spool Removal And Installation........................................................ 180 Auxiliary Solenoid Removal And Installation..................................................... 181 Solenoid Removal And Installation............................................................... 182 Lock Valve Removal And Installation............................................................. 183 Lift Arm Bypass Orifice Removal And Installation................................................ 185 Main Relief Valve Removal And Installation...................................................... 185 Auxiliary Relief Valve Removal And Installation................................................. 186 Check Valve Removal And Installation............................................................ 186 HYDRAULIC CONTROL VALVE (SJC)....................................................................... 189 Description..................................................................................... 189 Removal And Installation........................................................................ 189 Actuator Removal And Installation (In Loader)................................................... 194 Actuator Removal And Installation (Out Of Loader)............................................... 195 Identification Chart............................................................................ 198 Mount Bracket Removal And Installation.......................................................... 199 Lift Load Check Valve Removal And Installation.................................................. 199 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 200 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 201 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 201 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 202 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 202 Port Relief Valve Removal And Installation...................................................... 203 Plug Removal And Installation................................................................... 205 End Cap Block Removal And Installation.......................................................... 206 Lift Spool Removal And Installation............................................................. 206 Lift Spool Disassembly And Assembly............................................................. 208 Tilt Spool Removal And Installation............................................................. 209 Auxiliary Spool Removal And Installation........................................................ 211 Auxiliary Solenoid Removal And Installation..................................................... 212 Solenoid Removal And Installation............................................................... 213 Lock Valve Removal And Installation............................................................. 214 Lift Arm Bypass Orifice Removal And Installation................................................ 216 Main Relief Valve Removal And Installation...................................................... 216 Auxiliary Relief Valve Removal And Installation................................................. 217 Check Valve Removal And Installation............................................................ 217 LIFT ARM BYPASS CONTROL VALVE....................................................................... 219 Description..................................................................................... 219 Testing......................................................................................... 219 Removal And Installation........................................................................ 220 Bracket Removal And Installation................................................................ 221 Disassembly And Assembly........................................................................ 221 HYDRAULIC PUMP...................................................................................... 223 Description..................................................................................... 223 Pump Test At Quick Couplers..................................................................... 223 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..................................................................... 233 Direct Pump Test (Standard Section)............................................................. 234 Direct Pump Test (Charge Section)............................................................... 235 Direct Pump Test (High Flow Section)............................................................ 237 High Flow Relief Valve Adjustment............................................................... 239 High Flow Relief Valve Removal And Installation................................................. 241 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.................................................................... 297 Removal And Installation........................................................................ 298 Parts Identification............................................................................ 300 Disassembly And Assembly........................................................................ 302 HYDROSTATIC DRIVE MOTOR (TWO-SPEED)................................................................. 315 Description..................................................................................... 315 Removing And Replacing Fluid.................................................................... 315 Removal And Installation........................................................................ 316 Parts Identification............................................................................ 318 Disassembly And Assembly........................................................................ 320 HYDROSTATIC DRIVE MOTOR (LATER MODELS WITH EIGHT TRACK SPROCKET BOLTS).............................. 333 Description..................................................................................... 333 Removing And Replacing Fluid.................................................................... 333 Removal And Installation........................................................................ 334 Parts Identification (Single Speed)............................................................. 336 Parts Identification (Two-Speed)................................................................ 338 Disassembly And Assembly........................................................................ 340 CHARGE PRESSURE..................................................................................... 355 Description..................................................................................... 355 Testing......................................................................................... 355 Sender Removal And Installation................................................................. 357 Adjusting....................................................................................... 358 HYDROSTATIC PUMP.................................................................................... 359 Description..................................................................................... 359 Removal And Installation........................................................................ 360 Hydrostatic Pump Startup........................................................................ 361 Replenishing / High Pressure Relief Valve Removal And Installation.............................. 361 Parts Identification (Left Half)................................................................ 362 Parts Identification (Right Half)............................................................... 363 Disassembly..................................................................................... 364 Assembly........................................................................................ 371 HYDROSTATIC PUMP (SJC).............................................................................. 379 Description..................................................................................... 379 Hydraulic Controller Removal And Installation................................................... 380 Removal And Installation........................................................................ 382 Hydrostatic Pump Startup........................................................................ 384 Parts Identification............................................................................ 385 High Pressure Relief And Bypass Valve........................................................... 386 Charge Relief Valve............................................................................. 387 Disassembly..................................................................................... 388 Inspection...................................................................................... 397 Assembly........................................................................................ 401 Mechanical Neutral Adjustment................................................................... 411 Hydraulic Controller Neutral Adjustment......................................................... 414 DRIVE BELT.......................................................................................... 417 Belt Adjustment................................................................................. 417 Stop Adjustment................................................................................. 417 Belt Replacement................................................................................ 418 Tensioner Pulley Removal And Installation (Earlier Models)...................................... 420 Tensioner Pulley Disassembly And Assembly....................................................... 420 Tensioner Pulley Removal And Installation (Later Models)........................................ 421 Tensioner Pulley Disassembly And Assembly....................................................... 421 TWO-SPEED / BRAKE VALVE............................................................................. 423 Description..................................................................................... 423 Valve Block Removal And Installation............................................................ 424 Valve Block Disassembly And Assembly............................................................ 426 DRAIN MANIFOLD...................................................................................... 429 Description..................................................................................... 429 Removal And Installation........................................................................ 429 DRIVE SYSTEM............................................................................................ 431 BRAKE (SINGLE SPEED)................................................................................ 433 Description..................................................................................... 433 Block Removal And Installation.................................................................. 433 Block Disassembly And Assembly.................................................................. 434 BRAKE (TWO-SPEED)................................................................................... 437 Description..................................................................................... 437 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED)...................................................... 439 Description..................................................................................... 439 Checking (Solid-Mounted Undercarriage).......................................................... 441 Adjusting (Solid-Mounted Undercarriage) (Earlier Models With Two Track Tension Fittings)........ 442 Adjusting (Solid-Mounted Undercarriage) (Later Models With One Track Tension Fitting)........... 443 Track Removal And Installation.................................................................. 444 Idler (Front) Removal And Installation.......................................................... 447 Track Tensioner Removal And Installation........................................................ 448 Track Tensioner Disassembly And Assembly........................................................ 449 Idler (Rear) Removal And Installation........................................................... 451 Roller Removal And Installation................................................................. 451 Sprocket Removal And Installation (Single Speed)................................................ 452 Sprocket Removal And Installation (Two-Speed)................................................... 452 Later Models With Eight Sprocket Bolts.......................................................... 452 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION).................................................. 453 Description..................................................................................... 453 Checking (Roller Suspension Undercarriage)...................................................... 455 Adjusting (Roller Suspension Undercarriage) (Earlier Models With Two Track Tension Fittings).... 456 Adjusting (Roller Suspension Undercarriage) (Later Models With One Track Tension Fitting)....... 457 Track Removal And Installation.................................................................. 458 Idler (Front) Removal And Installation.......................................................... 461 Track Tensioner Removal And Installation........................................................ 462 Track Tensioner Disassembly And Assembly........................................................ 463 Idler (Rear) Removal And Installation........................................................... 465 Roller Removal And Installation................................................................. 465 Leaf Spring Removal And Installation............................................................ 466 Sprocket Removal And Installation (Single Speed)................................................ 467 Sprocket Removal And Installation (Two-Speed)................................................... 467 Later Models With Eight Sprocket Bolts.......................................................... 467 TRACK MAINTENANCE................................................................................... 469 Track Damage Identification..................................................................... 469 MAINFRAME............................................................................................... 481 SEAT BAR............................................................................................ 485 Description..................................................................................... 485 Removal And Installation........................................................................ 485 Disassembly And Assembly........................................................................ 486 Compression Spring Disassembly And Assembly..................................................... 487 OPERATOR CAB........................................................................................ 489 Gas Spring Removal And Installation............................................................. 489 Gas Spring Bracket Disassembly And Assembly..................................................... 490 Removal And Installation........................................................................ 490 OPERATOR SEAT....................................................................................... 493 Removal And Installation........................................................................ 493 Seat Belt Removal And Installation (Retractable)................................................ 493 Seat Belt And Bracket Removal And Installation (Standard)....................................... 494 Seat Belt Bracket Removal And Installation...................................................... 494 OPERATOR SEAT (SUSPENSION).......................................................................... 495 Removal And Installation........................................................................ 495 Slide Rail Removal And Installation............................................................. 495 Seat Belt Removal And Installation.............................................................. 496 Lower Cushion Removal........................................................................... 496 Lower Cushion Installation...................................................................... 497 Back Cushion Removal And Installation........................................................... 497 Shock Removal And Installation.................................................................. 498 3-Point Seat Belt Removal And Installation...................................................... 498 BOB-TACH (HAND LEVER)............................................................................... 501 Description..................................................................................... 501 Removal And Installation........................................................................ 501 Lever And Wedge Disassembly And Assembly........................................................ 503 Pivot Pin Bushing And Seal Removal And Installation............................................. 506 BOB-TACH (POWER).................................................................................... 507 Description..................................................................................... 507 Removal And Installation........................................................................ 507 Lever And Wedge Disassembly And Assembly........................................................ 510 Pivot Pin Bushing And Seal Removal And Installation............................................. 512 LIFT ARMS........................................................................................... 513 Stabilizer Bar Removal And Installation......................................................... 513 Link Removal And Installation................................................................... 514 Removal And Installation........................................................................ 515 REAR GRILLE......................................................................................... 519 Removing........................................................................................ 519 Installing...................................................................................... 519 Shield Removal And Installation................................................................. 520 ENGINE COVER........................................................................................ 521 Removal And Installation........................................................................ 521 REAR DOOR (TAILGATE)................................................................................ 523 Removal And Installation........................................................................ 523 Striker Removal And Installation................................................................ 524 Striker Disassembly And Assembly................................................................ 524 Striker (Adjusting)............................................................................. 524 Latch Removal And Installation.................................................................. 525 FUEL TANK........................................................................................... 527 Removal And Installation........................................................................ 527 Fuel Level Sender Removal And Installation...................................................... 528 Fuel Fill Screen Removal And Installation....................................................... 529 CONTROL PEDALS AND LINKAGES (SCPA).................................................................. 531 Description..................................................................................... 531 Pedal Removal And Installation.................................................................. 531 Linkage Removal And Installation................................................................ 532 Pedal (Adjusting)............................................................................... 533 Floor Pan Removal And Installation.............................................................. 534 CONTROL PANEL (SJC)................................................................................. 535 Description..................................................................................... 535 Removal And Installation........................................................................ 535 CONTROL PANEL (SCPA)................................................................................ 537 Description..................................................................................... 537 Removal And Installation........................................................................ 537 CONTROL HANDLE / LEVER (SJC)........................................................................ 539 Description..................................................................................... 539 Joystick Testing................................................................................ 539 Joystick Removal And Installation............................................................... 540 CONTROL HANDLE / LEVER (SCPA)....................................................................... 541 Description..................................................................................... 541 Steering Handle Testing......................................................................... 541 Steering Handle Removal And Installation........................................................ 542 ACCESS PANEL (INSIDE) (SJC)......................................................................... 543 Removal And Installation (Left)................................................................. 543 Removal And Installation (Right)................................................................ 543 ACCESS PANEL (INSIDE) (SCPA)........................................................................ 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........................................................................ 567 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....................................................................... 662 Glossary Of Electrical Symbols.................................................................. 662 Standard Cab Harness Connectors................................................................. 665 Deluxe Cab Harness Connectors................................................................... 666 Mainframe Harness Connectors.................................................................... 667 Engine Harness Connectors....................................................................... 668 Description..................................................................................... 669 Troubleshooting................................................................................. 670 Fuse And Relay Location / Identification........................................................ 671 Solenoid Testing................................................................................ 676 BATTERY............................................................................................. 678 Removal And Installation........................................................................ 678 Servicing....................................................................................... 679 Maintaining Battery Charge Level................................................................ 679 Battery Service During Machine Storage.......................................................... 679 Battery Testing................................................................................. 680 Battery Charging................................................................................ 680 Using A Booster Battery (Jump Starting)......................................................... 681 ALTERNATOR.......................................................................................... 682 Belt Adjustment................................................................................. 682 Belt Replacement................................................................................ 682 Charging System Inspection...................................................................... 683 Alternator Voltage Testing...................................................................... 684 Low Voltage Testing............................................................................. 684 High Voltage Testing............................................................................ 685 Removal And Installation........................................................................ 686 Parts Identification............................................................................ 688 STARTER............................................................................................. 690 Testing......................................................................................... 690 Removal And Installation........................................................................ 690 Parts Identification............................................................................ 691 INSTRUMENT PANELS................................................................................... 692 Left Panel...................................................................................... 692 Display Screen.................................................................................. 694 Right Panel (Standard Key Panel)................................................................ 695 Right Panel (Keyless Start Panel)............................................................... 696 Right Panel (Deluxe Instrumentation Panel)...................................................... 697 Left Switch Panel............................................................................... 699 Right Switch Panel.............................................................................. 699 Left Side Lower Panel........................................................................... 700 Right Side Lower Panel.......................................................................... 700 Left Panel Removal And Installation............................................................. 701 Right Panel (Standard Key Panel) Removal And Installation....................................... 701 Right Panel (Keyless Start Panel) Removal And Installation...................................... 702 Right Panel (Deluxe Instrumentation Panel) Removal And Installation............................. 702 Key Switch Disassembly And Assembly............................................................. 703 Alarm Disassembly And Assembly.................................................................. 703 Left Switch Panel Removal And Installation...................................................... 704 Right Switch Panel Removal And Installation..................................................... 704 LIGHTS.............................................................................................. 706 Front Removal And Installation.................................................................. 706 Rear Removal And Installation................................................................... 707 Cab Light Removal And Installation.............................................................. 707 BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY).......................................................... 708 Description..................................................................................... 708 Connector Identification........................................................................ 709 Removal And Installation........................................................................ 715 BOBCAT CONTROLLER (ACS)............................................................................. 716 Description..................................................................................... 716 Connector And Wire Identification............................................................... 717 Removal And Installation........................................................................ 718 BOBCAT CONTROLLER (SJC) (DRIVE)..................................................................... 720 Description..................................................................................... 720 Connector Identification........................................................................ 721 Removal And Installation........................................................................ 723 BOBCAT CONTROLLER (SCPA) (DRIVE).................................................................... 724 Description..................................................................................... 724 Connector Identification........................................................................ 725 Removal And Installation........................................................................ 727 ENGINE CONTROL UNIT (ECU)........................................................................... 728 Description..................................................................................... 728 Cleaning........................................................................................ 729 Removal And Installation........................................................................ 730 DIAGNOSTIC SERVICE CODES............................................................................ 732 Viewing Service Codes........................................................................... 732 Service Codes List.............................................................................. 733 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)............................................................. 748 Description..................................................................................... 748 Operation....................................................................................... 748 Inspecting The BICS™ (Engine STOPPED - Key ON).................................................. 749 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)............ 749 Inspecting The Seat Bar Sensor (Engine RUNNING)................................................. 749 Inspecting The Traction Lock And Parking Brake (Engine RUNNING)................................. 749 Inspecting The Lift Arm Bypass Control.......................................................... 749 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)................................ 749 Troubleshooting................................................................................. 750 SEAT BAR SENSOR..................................................................................... 752 Description..................................................................................... 752 Troubleshooting................................................................................. 752 Testing......................................................................................... 753 Removal......................................................................................... 754 Installation.................................................................................... 755 Bobcat Interlock Control System (BICS™) Circuit Test............................................ 757 TRACTION LOCK....................................................................................... 760 Description..................................................................................... 760 Troubleshooting................................................................................. 761 Inspecting...................................................................................... 762 ELECTRICAL / HYDRAULIC CONTROLS (SJC)............................................................... 764 Identification Chart............................................................................ 764 Description..................................................................................... 765 Identification Chart ACD Group 0................................................................ 766 Identification Chart ACD Group 1................................................................ 767 Identification Chart ACD Group 2................................................................ 768 Identification Chart ACD Group 3................................................................ 769 ELECTRICAL / HYDRAULIC CONTROLS (SCPA).............................................................. 770 Identification Chart............................................................................ 770 Description..................................................................................... 771 Identification Chart ACD Group 0................................................................ 772 Identification Chart ACD Group 1................................................................ 773 Identification Chart ACD Group 2................................................................ 774 Identification Chart ACD Group 3................................................................ 775 SERVICE PC (LAPTOP COMPUTER)........................................................................ 776 Connecting Remote Start Tool.................................................................... 776 Connecting Remote Start Tool (Service Tool)..................................................... 776 CALIBRATION......................................................................................... 778 Description..................................................................................... 778 Actuator Testing................................................................................ 778 Lift And Tilt Calibration (SJC)................................................................. 781 Hydrostatic Pump Calibration (SJC).............................................................. 783 Hydrostatic Pump Calibration (SCPA)............................................................. 788 STEERING DRIFT COMPENSATION (OPERATOR MODE)......................................................... 794 Description..................................................................................... 794 Operation....................................................................................... 794 STEERING DRIFT COMPENSATION (SERVICE MODE).......................................................... 796 Description..................................................................................... 796 Operation....................................................................................... 796 CONTROL PANEL SETUP................................................................................. 798 Right Panel Setup (Deluxe Instrumentation Panel)................................................ 798 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....................................................... 802 Password Description............................................................................ 802 Changing The Owner Password..................................................................... 802 Changing The User Passwords..................................................................... 803 Password Lockout Feature........................................................................ 803 PASSWORD SETUP (KEYLESS START PANEL)................................................................ 804 Password Description............................................................................ 804 Changing The Owner Password..................................................................... 804 Password Lockout Feature........................................................................ 804 MAINTENANCE CLOCK................................................................................... 806 Description..................................................................................... 806 Setup........................................................................................... 807 Reset........................................................................................... 810 BACK-UP ALARM SYSTEM................................................................................ 812 Description..................................................................................... 812 Inspection...................................................................................... 812 Troubleshooting (Joystick)...................................................................... 813 Alarm Removal And Installation.................................................................. 814 FRONT HORN.......................................................................................... 816 Removal And Installation........................................................................ 816 Troubleshooting................................................................................. 817 Troubleshooting (Joystick)...................................................................... 818 ENGINE SPEED CONTROL (HAND)......................................................................... 820 Removal And Installation........................................................................ 820 ENGINE SPEED CONTROL (FOOT)......................................................................... 822 Removal And Installation........................................................................ 822 Disassembly And Assembly........................................................................ 823 Foot Throttle Calibration....................................................................... 825 CAMSHAFT AND CRANKSHAFT POSITION SENSOR............................................................. 828 Removal And Installation........................................................................ 828 TELEMATICS.......................................................................................... 830 Description..................................................................................... 830 Removal And Installation........................................................................ 830 Procedure....................................................................................... 831 ENGINE SERVICE.......................................................................................... 832 ENGINE INFORMATION.................................................................................. 836 Description..................................................................................... 836 Specifications.................................................................................. 837 Sensor Location................................................................................. 839 Torque Values................................................................................... 845 Troubleshooting................................................................................. 847 Engine Removal And Installation................................................................. 849 Engine Mount Replacement........................................................................ 860 Compression - Testing........................................................................... 862 Injector Signal - Testing....................................................................... 864 Injector Signal - Testing (In-Line)............................................................. 866 Oil Pressure Testing (At Oil Sensor On Block)................................................... 868 Oil Pressure Testing (At Turbocharger Oil Inlet)................................................ 870 DIESEL OXIDATION CATALYST (DOC)..................................................................... 872 Removal And Installation........................................................................ 872 AIR CLEANER......................................................................................... 874 Housing Removal And Installation................................................................ 874 ENGINE COOLING SYSTEM............................................................................... 876 Radiator / Oil Cooler Removal And Installation.................................................. 876 Hydraulic Fan Description....................................................................... 879 Reversible Hydraulic Fan Description............................................................ 879 Fan Duct Removal And Installation............................................................... 879 Hydraulic Fan Motor Assembly Removal And Installation........................................... 880 Hydraulic Fan Motor Removal And Installation.................................................... 881 Hydraulic Fan Motor Disassembly And Assembly.................................................... 883 Blower Housing Removal And Installation......................................................... 891 Water Pump Removal And Installation............................................................. 892 Thermostat Housing Removal And Installation..................................................... 893 Thermostat - Testing............................................................................ 893 LUBRICATION SYSTEM.................................................................................. 894 Description..................................................................................... 894 Oil Pan Removal And Installation................................................................ 895 Oil Pump Removal And Installation............................................................... 896 Oil Pump Relief Valve Description............................................................... 897 Oil Suction Tube Removal And Installation....................................................... 897 Oil Cooler Removal And Installation............................................................. 898 Oil Filter Head Removal And Installation........................................................ 898 Oil Cooler Bypass Description................................................................... 899 FUEL SYSTEM......................................................................................... 900 Description..................................................................................... 900 High Pressure Pump Removal And Installation..................................................... 901 High Pressure Pump Drive Gear Removal And Installation.......................................... 902 Fuel Cooler Removal And Installation............................................................ 903 Fuel Bypass Valve Removal And Installation...................................................... 903 Fuel Temperature Sensor Removal And Installation................................................ 903 Fuel Recirculation Valve Removal And Installation............................................... 904 Fuel Rail Assembly Removal And Installation..................................................... 905 Fuel Injector Removal And Installation.......................................................... 906 Injector Coding................................................................................. 909 Removing Air From The Fuel System............................................................... 911 CYLINDER HEAD....................................................................................... 914 Intake Air Heater Removal And Installation...................................................... 914 Intake Air Heater Tube Removal And Installation................................................. 915 Valve Clearance Adjustment...................................................................... 916 Cylinder Head Removal And Installation.......................................................... 918 Cylinder Head Disassembly And Assembly.......................................................... 921 Cylinder Head Inspection........................................................................ 922 Cylinder Head Top Clearance..................................................................... 923 Valve Step Height............................................................................... 924 Valve Stem Height............................................................................... 924 Valve Guide..................................................................................... 925 Valve........................................................................................... 925 Valve Spring.................................................................................... 926 Rocker Arm Shaft Disassembly And Assembly....................................................... 927 Rocker Arm Shaft Inspection..................................................................... 928 Push Rod Inspection............................................................................. 928 CRANKSHAFT AND PISTONS.............................................................................. 930 Piston And Connecting Rod Removal And Installation.............................................. 930 Piston And Connecting Rod Inspection............................................................ 931 Timing Wheel Removal And Installation........................................................... 933 Crankshaft Removal And Installation............................................................. 935 Cylinder Block Inspection....................................................................... 937 Crankshaft Inspection........................................................................... 939 Connecting Rod Inspection....................................................................... 939 Engine Component Class.......................................................................... 940 CAMSHAFT............................................................................................ 942 Removal And Installation........................................................................ 942 Inspecting...................................................................................... 943 GEARCASE............................................................................................ 946 Gear Backlash................................................................................... 946 Gear End Play................................................................................... 946 Gear Timing..................................................................................... 947 Idle Gear Removal And Installation.............................................................. 948 Idle Gear Inspection............................................................................ 948 TURBOCHARGER........................................................................................ 950 Description..................................................................................... 950 Removal And Installation........................................................................ 950 Inspection...................................................................................... 952 FLYWHEEL AND HOUSING................................................................................ 954 Flywheel Removal And Installation............................................................... 954 Ring Gear Removal And Installation.............................................................. 954 Housing Removal And Installation................................................................ 955 EXHAUST GAS RECIRCULATION (EGR) SYSTEM.............................................................. 956 Description..................................................................................... 956 Removal And Installation........................................................................ 957 Disassembly And Assembly........................................................................ 958 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................ 960 AIR CONDITIONING SYSTEM FLOW........................................................................ 962 Description..................................................................................... 962 Chart........................................................................................... 963 Components...................................................................................... 964 Safety Equipment................................................................................ 967 REGULAR MAINTENANCE................................................................................. 968 Filters......................................................................................... 968 Belt Adjustment................................................................................. 969 Belt Replacement................................................................................ 969 Condenser....................................................................................... 970 Air Conditioning Lubrication.................................................................... 970 Air Conditioning Service Chart.................................................................. 971 Air Conditioning Evaporator / Heater Coil....................................................... 972 TROUBLESHOOTING..................................................................................... 974 Blower Motor Does Not Operate................................................................... 974 Blower Motor Operates Normally, But Air Flow Is Insufficient.................................... 974 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal...................... 974 The Compressor Does Not Operate At All, Or Operates Improperly.................................. 974 Gauge Pressure Related Troubleshooting.......................................................... 975 Troubleshooting Tree............................................................................ 977 Temperature / Pressure Chart.................................................................... 980 Poor A/C Performance............................................................................ 982 HVAC Repair And Leaks........................................................................... 983 Electrical System............................................................................... 984 Engine Coolant Bypassing The Heater Valve....................................................... 990 Heater Valve Not Opening Or Closing............................................................. 991 SYSTEM CHARGING AND RECLAMATION..................................................................... 992 Refrigerant Identification...................................................................... 992 Reclamation And Charging With Recovery / Charging Unit.......................................... 993 COMPRESSOR.......................................................................................... 996 Removal And Installation........................................................................ 996 Oil............................................................................................. 998 Oil Check....................................................................................... 999 CONDENSER...........................................................................................1000 Removal And Installation........................................................................1000 RECEIVER / DRIER....................................................................................1002 Receiver / Drier Removal And Installation.......................................................1002 Pressure Switch Removal And Installation........................................................1004 Schrader® Valve Removal And Installation........................................................1005 EVAPORATOR / HEATER UNIT............................................................................1006 Removal And Installation........................................................................1006 THERMOSTAT..........................................................................................1008 Description.....................................................................................1008 Removal And Installation........................................................................1009 EXPANSION VALVE.....................................................................................1010 Removal And Installation........................................................................1010 EVAPORATOR COIL.....................................................................................1012 Removal And Installation........................................................................1012 HEATER COIL.........................................................................................1014 Removal And Installation........................................................................1014 BLOWER FAN..........................................................................................1016 Removal And Installation........................................................................1016 Disassembly And Assembly........................................................................1016 HEATER VALVE........................................................................................1020 Removal And Installation........................................................................1020 EVAPORATOR / HEATER COVER...........................................................................1022 Removing........................................................................................1022 Installing......................................................................................1022 SPECIFICATIONS..........................................................................................1024 (T740) LOADER SPECIFICATIONS........................................................................1026 Machine Dimensions..............................................................................1026 Performance.....................................................................................1027 Engine..........................................................................................1027 Drive System....................................................................................1028 Controls........................................................................................1028 Hydraulic System................................................................................1029 Electrical System...............................................................................1030 Capacities......................................................................................1030 Tracks..........................................................................................1031 Ground Pressure.................................................................................1031 TECHINCAL SERVICE GUIDE SPECIFICATIONS..............................................................1032 Engine..........................................................................................1032 Engine Torques..................................................................................1032 Cooling System..................................................................................1032 Loader Torques..................................................................................1033 Hydraulic / Hydrostatic System..................................................................1033 Fuel Consumption................................................................................1033 TORQUE SPECIFICATIONS FOR BOLTS.....................................................................1034 Torque For General SAE Bolts....................................................................1034 Torque For General Metric Bolts.................................................................1035 HYDRAULIC CONNECTION SPECIFICATIONS.................................................................1036 Straight Thread O-ring Fitting..................................................................1036 Flare Fitting...................................................................................1037 Tubelines And Hoses.............................................................................1037 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS........................................................1038 Specifications..................................................................................1038 CONVERSIONS.........................................................................................1040 Decimal And Millimeter Equivalent Chart.........................................................1040 U.S. To Metric Conversion Chart.................................................................1040 SERVICE TOOLS REQUIRED..............................................................................1042 Remote Start Tools..............................................................................1042 Hydraulic Tools.................................................................................1043 Mainframe And Drive Tools.......................................................................1046 Electrical Tools................................................................................1049 Engine Tools....................................................................................1050 HVAC Tools......................................................................................1055 ALPHABETICAL INDEX......................................................................................1056
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