Bobcat T750 Compact Track Loader Service Manual SN ANKA11001 & Above – PDF DOWNLOAD
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Bobcat T750 Compact Track Loader Service Manual SN ANKA11001 & Above – PDF DOWNLOAD
Description
Bobcat T750 Compact Track Loader Service Manual SN ANKA11001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat T750 Compact Track Loader Service Manual SN ANKA11001 & Above – PDF DOWNLOAD
Language : English
Pages : 1276
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:
Bobcat T750 Compact Track Loader Service Manual SN ANKA11001 & 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:
TABLE OF CONTENTS:
Bobcat T750 Compact Track Loader Service Manual SN ANKA11001 & Above – PDF DOWNLOAD
MAINTENANCE SAFETY...................................................................................... 3 CONTENTS................................................................................................ 5 FOREWORD................................................................................................ 7 FOREWORD............................................................................................ 9 SAFETY INSTRUCTIONS................................................................................. 11 FIRE PREVENTION..................................................................................... 13 Maintenance..................................................................................... 13 Operation....................................................................................... 13 Electrical...................................................................................... 13 Hydraulic System................................................................................ 13 Fueling......................................................................................... 13 Starting........................................................................................ 13 Spark Arrester Exhaust System................................................................... 13 Welding And Grinding............................................................................ 14 Fire Extinguishers.............................................................................. 14 SERIAL NUMBER LOCATIONS............................................................................. 15 Loader Serial Number............................................................................ 15 Engine Serial Number............................................................................ 15 DELIVERY REPORT..................................................................................... 16 LOADER IDENTIFICATION............................................................................... 17 SAFETY AND MAINTENANCE.................................................................................. 19 LIFTING AND BLOCKING THE LOADER..................................................................... 23 Procedure....................................................................................... 23 LIFT ARM SUPPORT DEVICE............................................................................. 25 Installing...................................................................................... 25 Removing........................................................................................ 26 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 AIR CLEANER SERVICE................................................................................. 53 Replacing Filter Elements....................................................................... 53 ENGINE COOLING SYSTEM............................................................................... 55 Maintenance Platform............................................................................ 55 Cooling System Identification................................................................... 55 Cleaning (Earlier Models)....................................................................... 56 Cleaning (Later Models)......................................................................... 58 Checking Level.................................................................................. 60 Removing And Replacing Coolant.................................................................. 60 FUEL SYSTEM......................................................................................... 61 Fuel Specifications............................................................................. 61 Biodiesel Blend Fuel............................................................................ 61 Filling The Fuel Tank........................................................................... 62 Fuel Filter..................................................................................... 63 Removing Air From The Fuel System............................................................... 63 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 Hydraulic / Hydrostatic Filter Identification................................................... 72 Removing And Replacing Hydraulic / Hydrostatic Filter (Earlier Models).......................... 73 Removing And Replacing Hydraulic / Hydrostatic Filter (Later Models)............................ 74 Removing And Replacing Hydraulic Charge Filter.................................................. 75 Breather Cap.................................................................................... 77 BOB-TACH (HAND LEVER)............................................................................... 79 Inspection And Maintenance...................................................................... 79 BOB-TACH (POWER).................................................................................... 81 Inspection And Maintenance...................................................................... 81 LUBRICATING THE LOADER.............................................................................. 83 Lubrication Locations........................................................................... 83 Track Roller And Idler Lubrication.............................................................. 85 SPARK ARRESTER MUFFLER.............................................................................. 87 Cleaning Procedure.............................................................................. 87 PIVOT PINS.......................................................................................... 89 Inspection And Maintenance...................................................................... 89 LOADER STORAGE AND RETURN TO SERVICE................................................................ 91 Storage......................................................................................... 91 Return To Service............................................................................... 91 STOPPING THE ENGINE AND LEAVING THE LOADER.......................................................... 93 Procedure....................................................................................... 93 EMERGENCY EXIT...................................................................................... 95 Rear Window Identification...................................................................... 95 Rear Window Removal (Latches)................................................................... 95 Rear Window Removal (Rubber Cord)............................................................... 95 External Access (Rear Window With Latches)...................................................... 96 External Access (Rear Window With Rubber Cord).................................................. 96 Front Door...................................................................................... 96 SEAT BELT........................................................................................... 99 Inspection And Maintenance...................................................................... 99 HYDRAULIC SYSTEM........................................................................................ 101 HYDRAULIC / HYDROSTATIC SCHEMATICS.................................................................. 109 HYDRAULIC SYSTEM INFORMATION........................................................................ 129 Glossary Of Hydraulic / Hydrostatic Symbols..................................................... 129 Troubleshooting................................................................................. 133 CYLINDER (LIFT)..................................................................................... 135 Testing......................................................................................... 135 Removal And Installation........................................................................ 136 Parts Identification............................................................................ 140 Disassembly..................................................................................... 141 Assembly........................................................................................ 143 CYLINDER (TILT)..................................................................................... 145 Testing......................................................................................... 145 Removal And Installation........................................................................ 146 Base End Pivot Pin Removal And Installation..................................................... 148 Parts Identification (Early Models)............................................................. 149 Parts Identification (Later Models)............................................................. 150 Disassembly..................................................................................... 151 Assembly........................................................................................ 154 CYLINDER (BOB-TACH)................................................................................. 159 Testing......................................................................................... 159 Removal And Installation........................................................................ 160 Parts Identification............................................................................ 161 Disassembly..................................................................................... 162 Assembly........................................................................................ 163 MAIN RELIEF VALVE (EARLY MODELS).................................................................... 167 Description..................................................................................... 167 Testing......................................................................................... 168 Adjusting....................................................................................... 170 Removal And Installation........................................................................ 171 MAIN RELIEF VALVE (LATER MODELS).................................................................... 173 Description..................................................................................... 173 Testing......................................................................................... 174 Main Relief Valve Adjustment.................................................................... 176 Main Relief Valve Removal And Installation...................................................... 176 Auxiliary Relief Valve Adjustment............................................................... 177 Auxiliary Relief Valve Removal And Installation................................................. 178 HYDRAULIC CONTROL VALVE (STANDARD) (EARLY MODELS)................................................... 179 Description..................................................................................... 179 Removal And Installation........................................................................ 180 Mount Bracket Removal And Installation.......................................................... 184 Identification Chart............................................................................ 185 Lift Load Check Valve Removal And Installation.................................................. 186 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 187 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 188 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 188 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 189 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 189 Port Relief Valve Removal And Installation...................................................... 190 Plug Removal And Installation................................................................... 191 Rubber Boot Removal And Installation............................................................ 192 End Cap Block Removal And Installation.......................................................... 193 Lift Spool And Detent Removal And Installation.................................................. 194 Lift Spool And Detent Disassembly And Assembly.................................................. 196 Lift Spool And Detent Removal And Installation.................................................. 201 Tilt Spool Removal And Installation............................................................. 204 Auxiliary Spool Removal And Installation........................................................ 206 Auxiliary Solenoid Removal And Installation..................................................... 208 Solenoid Removal And Installation............................................................... 209 Lock Valve Removal And Installation............................................................. 210 Lift Arm Bypass Orifice Removal And Installation................................................ 212 Main Relief Valve Removal And Installation...................................................... 212 Check Valve Removal And Installation............................................................ 213 HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS)................................................... 215 Description..................................................................................... 215 Removal And Installation........................................................................ 216 Mount Bracket Removal And Installation.......................................................... 220 Identification Chart............................................................................ 221 Lift Load Check Valve Removal And Installation.................................................. 222 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 223 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 224 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 224 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 225 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 225 Port Relief Valve Removal And Installation...................................................... 226 Plug Removal And Installation................................................................... 228 Rubber Boot Removal And Installation............................................................ 229 End Cap Block Removal And Installation.......................................................... 229 Lift Spool And Detent Removal And Installation.................................................. 230 Lift Spool And Detent Disassembly And Assembly.................................................. 232 Tilt Spool Removal And Installation............................................................. 238 Auxiliary Spool Removal And Installation........................................................ 240 Auxiliary Solenoid Removal And Installation..................................................... 241 Solenoid Removal And Installation............................................................... 242 Lock Valve Removal And Installation............................................................. 243 Lift Arm Bypass Orifice Removal And Installation................................................ 245 Main Relief Valve Removal And Installation...................................................... 245 Auxiliary Relief Valve Removal And Installation................................................. 246 Check Valve Removal And Installation............................................................ 246 HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLY MODELS)............................................... 249 Description..................................................................................... 249 Removal And Installation........................................................................ 249 Actuator Removal And Installation (In Loader)................................................... 254 Actuator Removal And Installation (Out Of Loader)............................................... 256 Identification Chart............................................................................ 259 Mount Bracket Removal And Installation.......................................................... 260 Lift Load Check Valve Removal And Installation.................................................. 260 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 261 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 262 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 262 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 263 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 263 Port Relief Valve Removal And Installation...................................................... 264 Plug Removal And Installation................................................................... 265 End Cap Block Removal And Installation.......................................................... 266 Lift Spool Removal And Installation............................................................. 266 Lift Spool Disassembly And Assembly............................................................. 268 Tilt Spool Removal And Installation............................................................. 270 Auxiliary Spool Removal And Installation........................................................ 272 Auxiliary Solenoid Removal And Installation..................................................... 273 Solenoid Removal And Installation............................................................... 274 Lock Valve Removal And Installation............................................................. 275 Lift Arm Bypass Orifice Removal And Installation................................................ 276 Main Relief Valve Removal And Installation...................................................... 276 Check Valve Removal And Installation............................................................ 277 HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS)............................................... 279 Description..................................................................................... 279 Removal And Installation........................................................................ 279 Actuator Removal And Installation (In Loader)................................................... 284 Actuator Removal And Installation (Out Of Loader)............................................... 285 Identification Chart............................................................................ 288 Mount Bracket Removal And Installation.......................................................... 289 Lift Load Check Valve Removal And Installation.................................................. 289 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 290 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 291 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 291 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 292 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 292 Port Relief Valve Removal And Installation...................................................... 293 Plug Removal And Installation................................................................... 295 End Cap Block Removal And Installation.......................................................... 296 Lift Spool Removal And Installation............................................................. 296 Lift Spool Disassembly And Assembly............................................................. 298 Tilt Spool Removal And Installation............................................................. 299 Auxiliary Spool Removal And Installation........................................................ 301 Auxiliary Solenoid Removal And Installation..................................................... 302 Solenoid Removal And Installation............................................................... 303 Lock Valve Removal And Installation............................................................. 304 Lift Arm Bypass Orifice Removal And Installation................................................ 306 Main Relief Valve Removal And Installation...................................................... 306 Auxiliary Relief Valve Removal And Installation................................................. 307 Check Valve Removal And Installation............................................................ 307 LIFT ARM BYPASS CONTROL VALVE....................................................................... 309 Description..................................................................................... 309 Testing......................................................................................... 309 Removal And Installation........................................................................ 310 Bracket Removal And Installation................................................................ 311 Disassembly And Assembly........................................................................ 311 HYDRAULIC PUMP...................................................................................... 313 Description..................................................................................... 313 Pump Test At Quick Couplers..................................................................... 313 Direct Pump Test (Standard Section)............................................................. 314 Direct Pump Test (Charge Section)............................................................... 316 Removal And Installation........................................................................ 318 Hydraulic Pump Startup.......................................................................... 320 Parts Identification............................................................................ 321 Disassembly And Assembly........................................................................ 322 HYDRAULIC PUMP (HIGH FLOW).......................................................................... 323 Description..................................................................................... 323 Pump Test At Quick Couplers..................................................................... 323 Direct Pump Test (Standard Section)............................................................. 324 Direct Pump Test (Charge Section)............................................................... 325 Direct Pump Test (High Flow Section)............................................................ 327 High Flow Relief Valve Adjustment............................................................... 329 High Flow Relief Valve Removal And Installation................................................. 330 Solenoid Removal And Installation............................................................... 331 Removal And Installation........................................................................ 332 Hydraulic Pump Startup.......................................................................... 334 Parts Identification............................................................................ 335 Disassembly And Assembly........................................................................ 336 HYDRAULIC / HYDROSTATIC FILTERS..................................................................... 337 Description..................................................................................... 337 Housing Removal And Installation................................................................ 337 HYDRAULIC FLUID RESERVOIR........................................................................... 339 Description..................................................................................... 339 Removal And Installation........................................................................ 339 Hydraulic Fluid Screen.......................................................................... 340 OIL COOLER.......................................................................................... 341 Description..................................................................................... 341 Removal And Installation........................................................................ 341 BUCKET POSITION VALVE............................................................................... 343 Description..................................................................................... 343 Solenoid Removal And Installation............................................................... 343 Solenoid Testing................................................................................ 345 Removal And Installation........................................................................ 345 Disassembly And Assembly........................................................................ 347 REAR AUXILIARY DIVERTER VALVE....................................................................... 349 Description..................................................................................... 349 Solenoid Testing................................................................................ 349 Removal And Installation........................................................................ 350 Disassembly And Assembly........................................................................ 351 BOB-TACH (POWER) BLOCK.............................................................................. 357 Description..................................................................................... 357 Removal And Installation........................................................................ 357 Disassembly And Assembly........................................................................ 359 BOB-TACH (POWER) BLOCK (S/N ANKA13975 AND ABOVE) ................................................... 367 Description..................................................................................... 367 Testing Relief Valve............................................................................ 368 Removal And Installation........................................................................ 370 Disassembly And Assembly........................................................................ 372 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK............................................................. 377 Description..................................................................................... 377 Removal And Installation........................................................................ 378 Disassembly And Assembly (FFI/FI)............................................................... 378 Disassembly And Assembly (FFH/FH)............................................................... 380 HYDROSTATIC SYSTEM...................................................................................... 383 HYDROSTATIC SYSTEM INFORMATION...................................................................... 385 Description..................................................................................... 385 Troubleshooting................................................................................. 386 HYDROSTATIC DRIVE MOTOR............................................................................. 387 Description..................................................................................... 387 Removing And Replacing Fluid.................................................................... 387 Removal And Installation........................................................................ 388 Parts Identification............................................................................ 390 Disassembly And Assembly........................................................................ 392 HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N ANKA11001 - ANKA13449)..................................... 405 Description..................................................................................... 405 Removing And Replacing Fluid.................................................................... 405 Removal And Installation........................................................................ 406 Parts Identification............................................................................ 408 Disassembly And Assembly........................................................................ 410 HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N ANKA13450 & ABOVE)......................................... 423 Description..................................................................................... 423 Removing And Replacing Fluid.................................................................... 423 Removal And Installation........................................................................ 424 Parts Identification............................................................................ 426 Disassembly And Assembly........................................................................ 428 CHARGE PRESSURE..................................................................................... 441 Description..................................................................................... 441 Testing......................................................................................... 441 Sender Removal And Installation................................................................. 443 Adjusting....................................................................................... 444 HYDROSTATIC PUMP.................................................................................... 447 Description..................................................................................... 447 Removal And Installation........................................................................ 448 Hydrostatic Pump Startup........................................................................ 449 Replenishing / High Pressure Relief Valve Removal And Installation.............................. 450 Parts Identification (Left Half)................................................................ 451 Parts Identification (Right Half)............................................................... 452 Disassembly..................................................................................... 453 Assembly........................................................................................ 460 HYDROSTATIC PUMP (SJC).............................................................................. 467 Description..................................................................................... 467 Hydraulic Controller Removal And Installation................................................... 468 Removal And Installation........................................................................ 470 Hydrostatic Pump Startup........................................................................ 472 Parts Identification............................................................................ 473 High Pressure Relief And Bypass Valve........................................................... 474 Charge Relief Valve............................................................................. 475 Disassembly..................................................................................... 476 Inspection...................................................................................... 485 Assembly........................................................................................ 489 Mechanical Neutral Adjustment................................................................... 499 Hydraulic Controller Neutral Adjustment......................................................... 502 DRIVE BELT.......................................................................................... 505 Belt Adjustment................................................................................. 505 Stop Adjustment................................................................................. 505 Belt Replacement................................................................................ 506 Tensioner Pulley Removal And Installation....................................................... 508 Tensioner Pulley Disassembly And Assembly....................................................... 509 TWO-SPEED / BRAKE VALVE (S/N ANKA11001 - ANKA13449)................................................. 511 Description..................................................................................... 511 Valve Block Removal And Installation............................................................ 512 Valve Block Disassembly And Assembly............................................................ 514 TWO-SPEED / BRAKE VALVE (S/N ANKA13450 & ABOVE)..................................................... 517 Description..................................................................................... 517 Valve Block Removal And Installation............................................................ 518 Valve Block Disassembly And Assembly............................................................ 520 DRAIN MANIFOLD...................................................................................... 523 Description..................................................................................... 523 Drain Manifold Removal And Installation......................................................... 523 DRIVE SYSTEM............................................................................................ 525 BRAKE............................................................................................... 527 Description..................................................................................... 527 Block Removal And Installation.................................................................. 527 Block Disassembly And Assembly.................................................................. 528 BRAKE (TWO-SPEED)................................................................................... 531 Description..................................................................................... 531 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED)...................................................... 533 Description..................................................................................... 533 Checking Tension................................................................................ 534 Adjusting Tension............................................................................... 535 Track Removal And Installation.................................................................. 536 Idler (Front) Removal And Installation.......................................................... 538 Track Tensioner Disassembly And Assembly........................................................ 541 Idler (Rear) Removal And Installation........................................................... 543 Roller Removal And Installation................................................................. 543 Sprocket Removal And Installation (Single Speed)................................................ 544 Sprocket Removal And Installation (Two-Speed)................................................... 544 Track Housing Removal And Installation.......................................................... 545 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION).................................................. 547 Description..................................................................................... 547 Checking Tension................................................................................ 548 Adjusting Tension............................................................................... 549 Track Removal And Installation.................................................................. 550 Idler (Front) Removal And Installation.......................................................... 552 Track Tensioner Disassembly And Assembly........................................................ 555 Idler (Rear) Removal And Installation........................................................... 557 Roller Removal And Installation................................................................. 557 Leaf Spring Removal And Installation............................................................ 558 Sprocket Removal And Installation (Single Speed)................................................ 559 Sprocket Removal And Installation (Two-Speed)................................................... 559 Track Housing Removal And Installation.......................................................... 560 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED) (S/N ANKA15001 AND ABOVE) ........................... 561 Description..................................................................................... 561 Checking (Solid-Mounted Undercarriage).......................................................... 563 Adjusting (Solid-Mounted Undercarriage) (Earlier Models With Two Track Tension Fittings)........ 564 Adjusting (Solid-Mounted Undercarriage) (Later Models With One Track Tension Fitting)........... 565 Track Removal And Installation.................................................................. 566 Idler (Front) Removal And Installation.......................................................... 569 Track Tensioner Removal And Installation........................................................ 570 Track Tensioner Disassembly And Assembly........................................................ 571 Idler (Rear) Removal And Installation........................................................... 573 Roller Removal And Installation................................................................. 573 Sprocket Removal And Installation (Single Speed)................................................ 574 Sprocket Removal And Installation (Two-Speed)................................................... 574 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION) (S/N ANKA15001 AND ABOVE) ....................... 575 Description..................................................................................... 575 Checking (Roller Suspension Undercarriage)...................................................... 577 Adjusting (Roller Suspension Undercarriage) (Earlier Models With Two Track Tension Fittings).... 578 Adjusting (Roller Suspension Undercarriage) (Later Models With One Track Tension Fitting)....... 579 Track Removal And Installation.................................................................. 580 Idler (Front) Removal And Installation.......................................................... 583 Track Tensioner Removal And Installation........................................................ 584 Track Tensioner Disassembly And Assembly........................................................ 585 Idler (Rear) Removal And Installation........................................................... 587 Roller Removal And Installation................................................................. 587 Leaf Spring Removal And Installation............................................................ 588 Sprocket Removal And Installation (Single Speed)................................................ 589 Sprocket Removal And Installation (Two-Speed)................................................... 589 TRACK MAINTENANCE................................................................................... 591 Track Damage Identification..................................................................... 591 MAINFRAME............................................................................................... 603 SEAT BAR............................................................................................ 607 Description..................................................................................... 607 Removal And Installation........................................................................ 607 Disassembly And Assembly........................................................................ 608 Compression Spring Disassembly And Assembly..................................................... 609 OPERATOR CAB........................................................................................ 611 Gas Spring Removal And Installation............................................................. 611 Gas Spring Bracket Disassembly And Assembly..................................................... 612 Removal And Installation........................................................................ 612 OPERATOR SEAT (SUSPENSION).......................................................................... 615 Removal And Installation........................................................................ 615 Slide Rail Removal And Installation............................................................. 615 Seat Belt Removal And Installation.............................................................. 616 Lower Cushion Removal........................................................................... 616 Lower Cushion Installation...................................................................... 617 Back Cushion Removal And Installation........................................................... 617 Shock Removal And Installation.................................................................. 618 3-Point Seat Belt Removal And Installation...................................................... 618 BOB-TACH (HAND LEVER)............................................................................... 621 Description..................................................................................... 621 Removal And Installation........................................................................ 621 Lever And Wedge Disassembly And Assembly........................................................ 623 Pivot Pin Bushing And Seal Removal And Installation............................................. 625 BOB-TACH (POWER).................................................................................... 627 Description..................................................................................... 627 Removal And Installation........................................................................ 627 Lever And Wedge Disassembly And Assembly........................................................ 630 Pivot Pin Bushing And Seal Removal And Installation............................................. 632 LIFT ARMS........................................................................................... 633 Stabilizer Bar Removal And Installation......................................................... 633 Link Removal And Installation................................................................... 634 Removal And Installation........................................................................ 635 REAR GRILLE......................................................................................... 639 Removal And Installation........................................................................ 639 REAR DOOR (TAILGATE)................................................................................ 641 Removal And Installation........................................................................ 641 Striker Removal And Installation................................................................ 642 Striker Disassembly And Assembly................................................................ 642 Striker (Adjusting)............................................................................. 642 Latch Removal And Installation (Early Models)................................................... 643 Latch Removal And Installation (Later Models)................................................... 644 FUEL TANK........................................................................................... 645 Removal And Installation........................................................................ 645 Fuel Level Sender Removal And Installation...................................................... 647 Fuel Fill Screen Removal And Installation....................................................... 647 CONTROL PEDALS AND LINKAGES......................................................................... 649 Description..................................................................................... 649 Pedal Removal And Installation.................................................................. 649 Linkage Removal And Installation................................................................ 650 Pedal (Adjusting)............................................................................... 651 Floor Pan Removal And Installation.............................................................. 652 CONTROL PEDALS AND LINKAGES (ACS)................................................................... 653 Description..................................................................................... 653 Pedal Removal And Installation.................................................................. 653 Linkage Removal And Installation................................................................ 654 Pedal (Adjusting)............................................................................... 654 Floor Pan Removal And Installation.............................................................. 655 CONTROL PANEL....................................................................................... 657 Description..................................................................................... 657 Removal And Installation........................................................................ 658 Disassembly And Assembly........................................................................ 659 Linkage Removal And Installation................................................................ 661 Pintle Arm Disassembly And Assembly............................................................. 665 Linkage Neutral (Adjusting)..................................................................... 666 Linkage Travel (Adjusting)...................................................................... 670 Shock Removal And Installation.................................................................. 674 CONTROL PANEL (SJC)................................................................................. 675 Description..................................................................................... 675 Removal And Installation........................................................................ 675 CONTROL HANDLE / LEVER.............................................................................. 677 Description..................................................................................... 677 Lever Removal And Installation.................................................................. 677 Boot Removal And Installation................................................................... 678 CONTROL HANDLE / LEVER (ACS)........................................................................ 679 Description..................................................................................... 679 Handle Sensor Removal And Installation.......................................................... 679 Handle Removal And Installation................................................................. 682 Handle Disassembly And Assembly................................................................. 683 Lever Removal And Installation.................................................................. 683 Boot Removal And Installation................................................................... 684 CONTROL HANDLE / LEVER (SJC)........................................................................ 685 Description..................................................................................... 685 Joystick Testing................................................................................ 685 Joystick Removal And Installation............................................................... 686 ACCESS PANEL (INSIDE)............................................................................... 687 Removal And Installation (Left)................................................................. 687 Removal And Installation (Right)................................................................ 687 ACCESS PANEL (INSIDE) (SJC)......................................................................... 689 Removal And Installation (Left)................................................................. 689 Removal And Installation (Right)................................................................ 689 WINDOW (REAR)....................................................................................... 691 Rear Window Identification...................................................................... 691 Removal And Installation (Latches).............................................................. 691 Disassembly And Assembly (Latches).............................................................. 692 Removal (Rubber Cord)........................................................................... 693 Installation (Rubber Cord)...................................................................... 694 WINDOW (TOP)........................................................................................ 697 Removal And Installation........................................................................ 697 WINDOW (SIDE)....................................................................................... 699 Removal And Installation........................................................................ 699 CAB DOOR............................................................................................ 701 Description..................................................................................... 701 Removal And Installation........................................................................ 701 Disassembly And Assembly........................................................................ 702 Aligning........................................................................................ 703 Adjusting....................................................................................... 704 Checking Operation.............................................................................. 704 ARMREST............................................................................................. 705 Description..................................................................................... 705 Removal And Installation........................................................................ 705 Disassembly And Assembly........................................................................ 706 LEFT SIDE LOWER PANEL............................................................................... 709 Removal And Installation........................................................................ 709 Disassembly And Assembly........................................................................ 711 RIGHT SIDE LOWER PANEL.............................................................................. 713 Removal And Installation........................................................................ 713 Disassembly And Assembly........................................................................ 714 HEADLINER........................................................................................... 717 Removal And Installation........................................................................ 717 ELECTRICAL SYSTEM AND ANALYSIS.......................................................................... 719 ELECTRICAL SCHEMATICS............................................................................... 725 ELECTRICAL SYSTEM INFORMATION....................................................................... 871 Glossary Of Electrical Symbols.................................................................. 871 Standard Cab Harness Connectors................................................................. 874 Deluxe Cab Harness Connectors................................................................... 875 Mainframe Harness Connectors.................................................................... 876 Description..................................................................................... 877 Troubleshooting................................................................................. 878 Fuse And Relay Location / Identification........................................................ 879 Solenoid Testing................................................................................ 881 BATTERY............................................................................................. 883 Removal And Installation........................................................................ 883 Servicing....................................................................................... 884 Using A Booster Battery (Jump Starting)......................................................... 885 ALTERNATOR.......................................................................................... 887 Belt Adjustment................................................................................. 887 Belt Replacement................................................................................ 887 Charging System Inspection...................................................................... 888 Alternator Voltage Testing...................................................................... 889 Low Voltage Testing............................................................................. 889 High Voltage Testing............................................................................ 890 Removal And Installation........................................................................ 891 Parts Identification............................................................................ 893 STARTER............................................................................................. 895 Testing......................................................................................... 895 Removal And Installation........................................................................ 895 Parts Identification............................................................................ 896 INSTRUMENT PANELS................................................................................... 897 Left Panel (Early Models)....................................................................... 897 Left Panel (Later Models)....................................................................... 899 Display Screen.................................................................................. 901 Right Panel (Standard Key Panel)................................................................ 902 Right Panel (Keyless Start Panel)............................................................... 903 Right Panel (Deluxe Instrumentation Panel)...................................................... 904 Left Switch Panel............................................................................... 906 Right Switch Panel.............................................................................. 906 Left Side Lower Panel........................................................................... 907 Right Side Lower Panel.......................................................................... 907 Left Panel Removal And Installation............................................................. 908 Right Panel (Standard Key Panel) Removal And Installation....................................... 908 Right Panel (Keyless Start Panel) Removal And Installation...................................... 909 Right Panel (Deluxe Instrumentation Panel) Removal And Installation............................. 909 Key Switch Disassembly And Assembly............................................................. 910 Alarm Disassembly And Assembly.................................................................. 910 Left Switch Panel Removal And Installation...................................................... 911 Right Switch Panel Removal And Installation..................................................... 911 LIGHTS.............................................................................................. 913 Front Removal And Installation.................................................................. 913 Rear Removal And Installation................................................................... 914 Cab Light Removal And Installation (Early Models)............................................... 914 Cab Light Removal And Installation (Later Models)............................................... 915 BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY).......................................................... 917 Description..................................................................................... 917 Connector Identification........................................................................ 918 Removal And Installation........................................................................ 924 BOBCAT CONTROLLER (ACS)............................................................................. 925 Description..................................................................................... 925 Connector And Wire Identification............................................................... 926 Removal And Installation........................................................................ 927 BOBCAT CONTROLLER (SJC) (DRIVE)..................................................................... 929 Description..................................................................................... 929 Connector Identification........................................................................ 930 Removal And Installation........................................................................ 932 SPEED SENSORS (SJC)................................................................................. 933 Description..................................................................................... 933 Testing......................................................................................... 933 Removal And Installation........................................................................ 934 DIAGNOSTIC SERVICE CODES............................................................................ 937 Viewing Service Codes........................................................................... 937 Service Codes List.............................................................................. 938 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)............................................................. 945 Description..................................................................................... 945 Inspecting The BICS™ (Engine STOPPED - Key ON).................................................. 946 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)............ 946 Inspecting The Seat Bar Sensor (Engine RUNNING)................................................. 946 Inspecting The Traction Lock And Parking Brake (Engine RUNNING)................................. 946 Inspecting The Lift Arm Bypass Control.......................................................... 946 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)................................ 946 Troubleshooting................................................................................. 947 SEAT BAR SENSOR..................................................................................... 949 Description..................................................................................... 949 Troubleshooting................................................................................. 949 Testing......................................................................................... 950 Removal And Installation........................................................................ 951 Bobcat Interlock Control System (BICS™) Circuit Test............................................ 954 TRACTION LOCK....................................................................................... 957 Description..................................................................................... 957 Troubleshooting................................................................................. 958 Inspecting...................................................................................... 959 CONTROL SYSTEM (ACS)................................................................................ 961 Description..................................................................................... 961 Troubleshooting................................................................................. 962 Handle Sensor Connector Disassembly And Assembly................................................ 963 Switch Handle Removal........................................................................... 964 Switch Handle Installation...................................................................... 966 Actuator Connector Disassembly And Assembly..................................................... 969 Handle Lock Solenoid Removal And Installation................................................... 970 Handle Lock Solenoid Disassembly And Assembly................................................... 970 Foot Sensor Removal And Installation............................................................ 971 Foot Sensor Disassembly And Assembly............................................................ 972 Foot Sensor Lock Solenoid Removal And Installation.............................................. 972 ELECTRICAL / HYDRAULIC CONTROLS..................................................................... 973 Identification Chart............................................................................ 973 Description..................................................................................... 974 Identification Chart ACD Group 0................................................................ 975 Identification Chart ACD Group 1................................................................ 976 Identification Chart ACD Group 2................................................................ 977 Identification Chart ACD Group 3................................................................ 978 ELECTRICAL / HYDRAULIC CONTROLS (ACS)............................................................... 979 Identification Chart............................................................................ 979 Description..................................................................................... 980 Identification Chart ACD Group 0................................................................ 981 Identification Chart ACD Group 1................................................................ 982 Identification Chart ACD Group 2................................................................ 983 Identification Chart ACD Group 3................................................................ 984 ELECTRICAL / HYDRAULIC CONTROLS (SJC)............................................................... 985 Identification Chart............................................................................ 985 Description..................................................................................... 986 Identification Chart ACD Group 0................................................................ 987 Identification Chart ACD Group 1................................................................ 988 Identification Chart ACD Group 2................................................................ 989 Identification Chart ACD Group 3................................................................ 990 SERVICE PC (LAPTOP COMPUTER)........................................................................ 991 Connecting Remote Start Tool.................................................................... 991 Connecting Remote Start Tool (Service Tool)..................................................... 991 CALIBRATION......................................................................................... 993 Description..................................................................................... 993 Actuator Testing................................................................................ 993 Lift And Tilt Calibration (SJC)................................................................. 996 Hydrostatic Pump Calibration (SJC).............................................................. 998 Lift And Tilt Calibration (ACS).................................................................1003 STEERING DRIFT COMPENSATION (OPERATOR MODE).........................................................1005 Description.....................................................................................1005 Operation.......................................................................................1005 STEERING DRIFT COMPENSATION (SERVICE MODE)..........................................................1007 Description.....................................................................................1007 Operation.......................................................................................1007 FLYWHEEL RPM SENSOR.................................................................................1009 Description.....................................................................................1009 Removal.........................................................................................1009 Installation....................................................................................1009 CONTROL PANEL SETUP.................................................................................1011 Right Panel Setup (Deluxe Instrumentation Panel)................................................1011 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL).......................................................1015 Password Description............................................................................1015 Changing The Owner Password.....................................................................1015 Changing The User Passwords.....................................................................1016 Password Lockout Feature........................................................................1016 PASSWORD SETUP (KEYLESS START PANEL)................................................................1017 Password Description............................................................................1017 Changing The Owner Password.....................................................................1017 Password Lockout Feature........................................................................1017 MAINTENANCE CLOCK...................................................................................1019 Description.....................................................................................1019 Setup...........................................................................................1020 Reset...........................................................................................1023 BACK-UP ALARM SYSTEM................................................................................1025 Description.....................................................................................1025 Inspecting......................................................................................1025 Adjusting Switch Position.......................................................................1026 Troubleshooting (Standard And ACS)..............................................................1027 Troubleshooting (Joystick)......................................................................1028 Alarm Removal And Installation..................................................................1029 Switch Removal And Installation.................................................................1029 FRONT HORN..........................................................................................1031 Removal And Installation........................................................................1031 Troubleshooting.................................................................................1032 Troubleshooting (Joystick)......................................................................1033 ENGINE SERVICE..........................................................................................1035 ENGINE INFORMATION..................................................................................1039 Description.....................................................................................1039 Specifications..................................................................................1040 Torque Values...................................................................................1043 Troubleshooting.................................................................................1043 Engine Removal And Installation.................................................................1045 Engine Mount Replacement........................................................................1052 Compression - Testing...........................................................................1053 ENGINE SPEED CONTROL................................................................................1055 Removal And Installation........................................................................1055 Disassembly And Assembly........................................................................1055 Cable Removal And Installation..................................................................1056 ENGINE SPEED CONTROL (SJC)..........................................................................1057 Removal And Installation........................................................................1057 Disassembly And Assembly........................................................................1058 MUFFLER.............................................................................................1061 Removal And Installation........................................................................1061 AIR CLEANER.........................................................................................1063 Housing Removal And Installation................................................................1063 ENGINE COOLING SYSTEM (EARLY MODELS)................................................................1065 Radiator Removal And Installation...............................................................1065 Hydraulic Fan Description.......................................................................1068 Fan Duct Removal And Installation...............................................................1068 Hydraulic Fan Motor Assembly Removal And Installation...........................................1069 Hydraulic Fan Motor Removal And Installation....................................................1069 Hydraulic Fan Motor Disassembly And Assembly....................................................1071 Blower Housing Removal And Installation.........................................................1073 Water Pump Removal And Installation.............................................................1073 Water Pump Disassembly And Assembly.............................................................1074 Thermostat Housing Removal And Installation.....................................................1074 Thermostat - Testing............................................................................1075 ENGINE COOLING SYSTEM (LATER MODELS)................................................................1077 Radiator Removal And Installation...............................................................1077 Hydraulic Fan Description.......................................................................1080 Fan Duct Removal And Installation...............................................................1080 Hydraulic Fan Motor Assembly Removal And Installation...........................................1081 Hydraulic Fan Motor Removal And Installation....................................................1082 Hydraulic Fan Motor Disassembly And Assembly....................................................1084 Blower Housing Removal And Installation.........................................................1089 Water Pump Removal And Installation.............................................................1090 Water Pump Disassembly And Assembly.............................................................1090 Thermostat Housing Removal And Installation.....................................................1091 Thermostat - Testing............................................................................1091 LUBRICATION SYSTEM..................................................................................1093 Oil Pan Removal And Installation................................................................1093 Oil Pump Removal And Installation...............................................................1094 Oil Pump Inspection.............................................................................1094 Oil Filter Cooler Removal And Installation......................................................1096 Engine Oil Pressure - Testing...................................................................1097 FUEL SYSTEM.........................................................................................1099 Fuel Shutoff Solenoid - Testing.................................................................1099 Fuel Shutoff Solenoid Removal And Installation..................................................1099 Fuel Injection Pump Assembly Removal............................................................1100 Fuel Injection Pump Assembly Installation.......................................................1104 Governor Housing Disassembly And Assembly.......................................................1106 Governor Disassembly And Assembly...............................................................1108 Fuel Camshaft Removal And Installation..........................................................1110 Fuel Injection Pump Removal.....................................................................1112 Fuel Injection Pump Installation................................................................1115 Fuel injection Pump - Timing....................................................................1118 Fuel Injector Removal And Installation..........................................................1122 Fuel Injector Nozzle Pressure - Testing.........................................................1123 Nozzle Spraying Condition.......................................................................1124 Valve Seat Tightness............................................................................1124 CYLINDER HEAD.......................................................................................1125 Intake Air Heater - Testing.....................................................................1125 Intake Air Heater Removal And Installation......................................................1125 Valve Clearance Adjustment......................................................................1126 Valve Timing - Checking.........................................................................1128 Cylinder Head Removal And Installation..........................................................1129 Cylinder Head Disassembly And Assembly..........................................................1131 Cylinder Head - Servicing.......................................................................1132 Cylinder Head Top Clearance.....................................................................1132 Valve Guide - Checking..........................................................................1133 Reconditioning The Valve And Valve Seat.........................................................1135 Valve Spring....................................................................................1137 Valve Tappets...................................................................................1138 Rocker Arm And Shaft - Measuring................................................................1139 Push Rod Alignment - Measuring..................................................................1139 CRANKSHAFT AND PISTONS..............................................................................1141 Piston And Connecting Rod Removal And Installation..............................................1141 Piston And Connecting Rod - Servicing...........................................................1143 Cylinder Bore - Measuring.......................................................................1147 Connecting Rod Alignment........................................................................1148 Crankshaft Gear Removal And Installation........................................................1148 Crankshaft And Bearings Removal.................................................................1149 Crankshaft And Bearings Installation............................................................1151 Crankshaft And Bearings - Servicing.............................................................1153 CAMSHAFT AND TIMING GEARS...........................................................................1159 Timing Gearcase Cover Removal And Installation..................................................1159 Timing Gears Backlash - Measuring...............................................................1160 Idler Gear And Camshaft Removal And Installation................................................1160 Camshaft - Servicing............................................................................1161 Idler Gear And Shaft - Servicing................................................................1163 TURBOCHARGER........................................................................................1165 Description.....................................................................................1165 Testing.........................................................................................1165 Removal And Installation........................................................................1166 FLYWHEEL AND HOUSING................................................................................1169 Flywheel Removal And Installation...............................................................1169 Ring Gear Removal And Installation..............................................................1169 Housing Removal And Installation................................................................1170 EXHAUST GAS RECIRCULATION (EGR) SYSTEM..............................................................1171 Description.....................................................................................1171 Testing.........................................................................................1172 Removal And Installation........................................................................1175 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................1177 AIR CONDITIONING SYSTEM FLOW........................................................................1179 Description.....................................................................................1179 Chart...........................................................................................1180 Components......................................................................................1181 Safety Equipment................................................................................1184 REGULAR MAINTENANCE.................................................................................1185 Filters.........................................................................................1185 Compressor Drive Belt Adjustment................................................................1186 Compressor Drive Belt Replacement...............................................................1186 Condenser.......................................................................................1186 Air Conditioning Lubrication....................................................................1186 Air Conditioning Service Chart..................................................................1187 Evaporator / Heater Coil........................................................................1188 TROUBLESHOOTING.....................................................................................1191 Blower Motor Does Not Operate...................................................................1191 Blower Motor Operates Normally, But Air Flow Is Insufficient....................................1191 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal......................1191 The Compressor Does Not Operate At All, Or Operates Improperly..................................1191 Gauge Pressure Related Troubleshooting..........................................................1192 Troubleshooting Tree............................................................................1194 Temperature / Pressure Chart....................................................................1197 Poor A/C Performance............................................................................1199 HVAC Repair And Leaks...........................................................................1200 Electrical System...............................................................................1201 Engine Coolant Bypassing The Heater Valve.......................................................1207 Heater Valve Not Opening Or Closing.............................................................1208 SYSTEM CHARGING AND RECLAMATION.....................................................................1211 Refrigerant Identification......................................................................1211 Reclamation And Charging With Recovery / Charging Unit..........................................1212 COMPRESSOR..........................................................................................1215 Removal And Installation........................................................................1215 Oil.............................................................................................1217 Oil Check.......................................................................................1218 CONDENSER...........................................................................................1219 Removal And Installation........................................................................1219 RECEIVER / DRIER....................................................................................1221 Receiver / Drier Removal And Installation.......................................................1221 Pressure Relief Valve Removal And Installation..................................................1222 Pressure Switch Removal And Installation........................................................1223 Schrader® Valve Removal And Installation .......................................................1224 EVAPORATOR / HEATER UNIT............................................................................1225 Removal And Installation........................................................................1225 THERMOSTAT..........................................................................................1227 Description.....................................................................................1227 Removal And Installation........................................................................1228 EXPANSION VALVE.....................................................................................1229 Removal And Installation........................................................................1229 EVAPORATOR COIL.....................................................................................1231 Removal And Installation........................................................................1231 HEATER COIL.........................................................................................1233 Removal And Installation........................................................................1233 BLOWER FAN..........................................................................................1235 Removal And Installation........................................................................1235 Disassembly And Assembly........................................................................1235 HEATER VALVE........................................................................................1239 Removal And Installation........................................................................1239 EVAPORATOR / HEATER COVER...........................................................................1241 Removal.........................................................................................1241 Installation....................................................................................1241 SPECIFICATIONS..........................................................................................1243 (T750) LOADER SPECIFICATIONS........................................................................1245 Machine Dimensions..............................................................................1245 Performance.....................................................................................1246 Engine..........................................................................................1247 Drive System....................................................................................1247 Controls........................................................................................1248 Hydraulic System................................................................................1248 Electrical System...............................................................................1249 Capacities......................................................................................1249 Tracks..........................................................................................1250 Ground Pressure.................................................................................1250 TORQUE SPECIFICATIONS FOR BOLTS.....................................................................1251 Torque For General SAE Bolts....................................................................1251 Torque For General Metric Bolts.................................................................1252 HYDRAULIC CONNECTION SPECIFICATIONS.................................................................1253 Straight Thread O-ring Fitting..................................................................1253 Flare Fitting...................................................................................1254 Tubelines And Hoses.............................................................................1254 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS........................................................1255 Specifications..................................................................................1255 CONVERSIONS.........................................................................................1257 Decimal And Millimeter Equivalent Chart.........................................................1257 U.S. To Metric Conversion Chart.................................................................1257 SERVICE TOOLS REQUIRED..............................................................................1259 Remote Start Tools..............................................................................1259 Hydraulic Tools.................................................................................1260 Mainframe And Drive Tools.......................................................................1262 Electrical Tools................................................................................1264 Engine Tools....................................................................................1265 HVAC Tools......................................................................................1270 ALPHABETICAL INDEX......................................................................................1271
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