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Bobcat T750 Compact Track Loader Service Manual SN ATF611001 & Above – PDF DOWNLOAD
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Bobcat T750 Compact Track Loader Service Manual SN ATF611001 & Above – PDF DOWNLOAD
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Description
Bobcat T750 Compact Track Loader Service Manual SN ATF611001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat T750 Compact Track Loader Service Manual SN ATF611001 & Above – PDF DOWNLOAD
Language : English
Pages : 1312
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T750 Compact Track Loader Service Manual SN ATF611001 & Above – PDF DOWNLOAD
FOREWORD:
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS / FOPS (Including side screens) is in good condition and is not modified.
2. Check that ROPS mounting hardware is tightened and is Bobcat approved.
3. The seat belt must be correctly installed, functional and in good condition.
4. The seat bar must be correctly adjusted, clean and lubricated.
5. Check lift arm support device, replace if damaged.
6. Machine signs (decals) must be legible and in the correct location.
7. Steering levers, hand controls and foot pedals must return to neutral (as applicable).
8. Check for correct function of the work lights.
9. The parking brake must function correctly.
10. Enclosure door latches must open and close freely.
11. Bob-Tach® attachment mounting system wedges and linkages must function correctly and be in good condition.
12. Safety treads must be in good condition.
13. Check for correct function of indicator lamps.
14. Check all machine fluid levels.
15. Inspect for fuel, oil or hydraulic fluid leaks.
SAFETY INSTRUCTIONS:
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
• The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
• Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
• The AEM Safety Manual delivered with the machine gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
TABLE OF CONTENTS:
Bobcat T750 Compact Track Loader Service Manual SN ATF611001 & Above – PDF DOWNLOAD
MAINTENANCE SAFETY.............................................................................. 3 CONTENTS........................................................................................ 5 FOREWORD........................................................................................ 7 FOREWORD.................................................................................... 9 SAFETY INSTRUCTIONS......................................................................... 11 FIRE PREVENTION............................................................................. 13 Maintenance............................................................................. 13 Operation............................................................................... 13 Electrical.............................................................................. 13 Hydraulic System........................................................................ 13 Fueling................................................................................. 13 Starting................................................................................ 13 Spark Arrester Exhaust System........................................................... 13 Welding And Grinding.................................................................... 14 Fire Extinguishers...................................................................... 14 SERIAL NUMBER LOCATIONS..................................................................... 15 Loader Serial Number.................................................................... 15 Engine Serial Number.................................................................... 15 DELIVERY REPORT............................................................................. 16 LOADER IDENTIFICATION....................................................................... 17 SAFETY AND MAINTENANCE.......................................................................... 19 LIFTING AND BLOCKING THE LOADER............................................................. 23 Procedure............................................................................... 23 LIFT ARM SUPPORT DEVICE..................................................................... 25 Description............................................................................. 25 Installing.............................................................................. 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 DIAGMASTER (SERVICE TOOL) KIT - 7024161..................................................... 51 Diagmaster (Service Tool)............................................................... 51 DST-i LED Table......................................................................... 52 DST-i Operation Status And Display Specification........................................ 52 Diagmaster (Service Tool) Procedure..................................................... 53 SERVICE SCHEDULE............................................................................ 57 Maintenance Intervals................................................................... 57 ENGINE AIR CLEANER.......................................................................... 59 Replacing Filter Elements............................................................... 59 ENGINE COOLING SYSTEM....................................................................... 61 Maintenance Platform.................................................................... 61 Cleaning................................................................................ 61 Checking And Adding Coolant............................................................. 63 Removing And Replacing Coolant.......................................................... 64 FUEL SYSTEM................................................................................. 65 Fuel Specifications..................................................................... 65 Biodiesel Blend Fuel.................................................................... 65 Filling The Fuel Tank................................................................... 66 Fuel Filter............................................................................. 67 Removing Air From The Fuel System....................................................... 68 ENGINE LUBRICATION SYSTEM................................................................... 69 Checking And Adding Engine Oil.......................................................... 69 Engine Oil Chart........................................................................ 69 Removing And Replacing Oil And Filter................................................... 70 Removing And Replacing Crankcase Ventilation Filter..................................... 72 HYDRAULIC / HYDROSTATIC SYSTEM.............................................................. 73 Checking And Adding Fluid............................................................... 73 Hydraulic / Hydrostatic Fluid Chart..................................................... 73 Removing And Replacing Hydraulic Fluid.................................................. 74 Removing And Replacing Hydraulic / Hydrostatic Filter................................... 76 Removing And Replacing Hydraulic Charge Filter.......................................... 77 Replacing Reservoir Breather Cap........................................................ 79 BOB-TACH (HAND LEVER)....................................................................... 81 Inspection And Maintenance.............................................................. 81 BOB-TACH (POWER)............................................................................ 83 Inspection And Maintenance.............................................................. 83 LUBRICATING THE LOADER...................................................................... 85 Lubrication Locations................................................................... 85 DIESEL PARTICULATE FILTER (DPF) SYSTEM...................................................... 89 Description............................................................................. 89 Remote Parked Regeneration.............................................................. 89 Service Regeneration.................................................................... 91 DPF Cleaning............................................................................ 91 PIVOT PINS.................................................................................. 93 Inspection And Maintenance.............................................................. 93 LOADER STORAGE AND RETURN TO SERVICE........................................................ 95 Storage................................................................................. 95 Return To Service....................................................................... 95 STOPPING THE ENGINE AND LEAVING THE LOADER.................................................. 97 Procedure............................................................................... 97 EMERGENCY EXIT.............................................................................. 99 Rear Window Identification.............................................................. 99 Rear Window Removal (Latches)........................................................... 99 Rear Window Removal (Rubber Cord)....................................................... 99 External Access (Rear Window With Latches).............................................. 100 External Access (Rear Window With Rubber Cord).......................................... 100 Front Door.............................................................................. 100 SEAT BELT................................................................................... 103 Inspection And Maintenance.............................................................. 103 HYDRAULIC SYSTEM................................................................................ 105 HYDRAULIC/HYDROSTATIC SCHEMATIC ............................................................ 111 HYDRAULIC SYSTEM INFORMATION................................................................ 123 Glossary Of Hydraulic / Hydrostatic Symbols............................................. 123 Troubleshooting......................................................................... 127 CYLINDER (LIFT)............................................................................. 129 Testing................................................................................. 129 Removal And Installation................................................................ 130 Parts Identification.................................................................... 134 Disassembly............................................................................. 135 Assembly................................................................................ 137 CYLINDER (TILT)............................................................................. 139 Testing................................................................................. 139 Removal And Installation................................................................ 140 Base End Pivot Pin Removal And Installation............................................. 142 Parts Identification (Earlier Models)................................................... 143 Parts Identification (Later Models)..................................................... 144 Disassembly............................................................................. 145 Assembly................................................................................ 148 CYLINDER (BOB-TACH)......................................................................... 153 Testing................................................................................. 153 Removal And Installation................................................................ 154 Parts Identification.................................................................... 155 Disassembly............................................................................. 156 Assembly................................................................................ 157 MAIN RELIEF VALVE (EARLIER MODELS).......................................................... 161 Description............................................................................. 161 Testing................................................................................. 162 Adjusting............................................................................... 164 Removal And Installation................................................................ 165 MAIN RELIEF VALVE (LATER MODELS)............................................................ 167 Description............................................................................. 167 Testing................................................................................. 168 Main Relief Valve Adjustment............................................................ 170 Main Relief Valve Removal And Installation.............................................. 170 Auxiliary Relief Valve Adjustment....................................................... 171 Auxiliary Relief Valve Removal And Installation......................................... 172 HYDRAULIC CONTROL VALVE (STANDARD) (EARLIER MODELS)......................................... 173 Description............................................................................. 173 Removal And Installation................................................................ 174 Mount Bracket Removal And Installation.................................................. 178 Identification Chart.................................................................... 179 Lift Load Check Valve Removal And Installation.......................................... 180 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................... 181 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................... 182 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........... 182 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........... 183 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............ 183 Port Relief Valve Removal And Installation.............................................. 184 Plug Removal And Installation........................................................... 185 Rubber Boot Removal And Installation.................................................... 186 End Cap Block Removal And Installation.................................................. 187 Lift Spool And Detent Removal And Installation.......................................... 188 Tilt Spool Removal And Installation..................................................... 198 Auxiliary Spool Removal And Installation................................................ 200 Auxiliary Solenoid Removal And Installation............................................. 202 Solenoid Removal And Installation....................................................... 203 Lock Valve Removal And Installation..................................................... 204 Lift Arm Bypass Orifice Removal And Installation........................................ 206 Main Relief Valve Removal And Installation.............................................. 206 Check Valve Removal And Installation.................................................... 207 HYDRAULIC CONTROL VALVE (STANDARD) (LATER MODELS)........................................... 209 Description............................................................................. 209 Removal And Installation................................................................ 210 Mount Bracket Removal And Installation.................................................. 214 Identification Chart.................................................................... 215 Lift Load Check Valve Removal And Installation.......................................... 216 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................... 217 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................... 218 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........... 218 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........... 219 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............ 219 Port Relief Valve Removal And Installation.............................................. 220 Plug Removal And Installation........................................................... 222 Rubber Boot Removal And Installation.................................................... 223 End Cap Block Removal And Installation.................................................. 223 Lift Spool And Detent Removal And Installation.......................................... 224 Tilt Spool Removal And Installation..................................................... 232 Auxiliary Spool Removal And Installation................................................ 234 Auxiliary Solenoid Removal And Installation............................................. 235 Solenoid Removal And Installation....................................................... 236 Lock Valve Removal And Installation..................................................... 237 Lift Arm Bypass Orifice Removal And Installation........................................ 239 Main Relief Valve Removal And Installation.............................................. 239 Auxiliary Relief Valve Removal And Installation......................................... 240 Check Valve Removal And Installation.................................................... 240 HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (EARLIER MODELS)..................................... 243 Description............................................................................. 243 Removal And Installation................................................................ 243 Actuator Removal And Installation (In Loader)........................................... 248 Actuator Removal And Installation (Out Of Loader)....................................... 250 Identification Chart.................................................................... 253 Mount Bracket Removal And Installation.................................................. 254 Lift Load Check Valve Removal And Installation.......................................... 254 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................... 255 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................... 256 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........... 256 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........... 257 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............ 257 Port Relief Valve Removal And Installation.............................................. 258 Plug Removal And Installation........................................................... 259 End Cap Block Removal And Installation.................................................. 260 Lift Spool Removal And Installation..................................................... 260 Lift Spool Disassembly And Assembly..................................................... 262 Tilt Spool Removal And Installation..................................................... 264 Auxiliary Spool Removal And Installation................................................ 266 Auxiliary Solenoid Removal And Installation............................................. 267 Solenoid Removal And Installation....................................................... 268 Lock Valve Removal And Installation..................................................... 269 Lift Arm Bypass Orifice Removal And Installation........................................ 270 Main Relief Valve Removal And Installation.............................................. 270 Check Valve Removal And Installation.................................................... 271 HYDRAULIC CONTROL VALVE (ACS) OR (SJC) (LATER MODELS)....................................... 273 Description............................................................................. 273 Removal And Installation................................................................ 273 Actuator Removal And Installation (In Loader)........................................... 278 Actuator Removal And Installation (Out Of Loader)....................................... 279 Identification Chart.................................................................... 282 Mount Bracket Removal And Installation.................................................. 283 Lift Load Check Valve Removal And Installation.......................................... 283 Load Check Valve Removal And Installation (Tilt And Auxiliary).......................... 284 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).......................... 285 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)........... 285 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)........... 286 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)............ 286 Port Relief Valve Removal And Installation.............................................. 287 Plug Removal And Installation........................................................... 289 End Cap Block Removal And Installation.................................................. 290 Lift Spool Removal And Installation..................................................... 290 Lift Spool Disassembly And Assembly..................................................... 292 Tilt Spool Removal And Installation..................................................... 293 Auxiliary Spool Removal And Installation................................................ 295 Auxiliary Solenoid Removal And Installation............................................. 296 Solenoid Removal And Installation....................................................... 297 Lock Valve Removal And Installation..................................................... 298 Lift Arm Bypass Orifice Removal And Installation........................................ 300 Main Relief Valve Removal And Installation.............................................. 300 Auxiliary Relief Valve Removal And Installation......................................... 301 Check Valve Removal And Installation.................................................... 301 LIFT ARM BYPASS CONTROL VALVE............................................................... 303 Description............................................................................. 303 Testing................................................................................. 303 Removal And Installation................................................................ 304 Bracket Removal And Installation........................................................ 305 Disassembly And Assembly................................................................ 305 HYDRAULIC PUMP.............................................................................. 307 Description............................................................................. 307 Pump Test At Quick Couplers............................................................. 307 Direct Pump Test (Standard Section)..................................................... 308 Direct Pump Test (Charge Section)....................................................... 310 Removal And Installation................................................................ 312 Hydraulic Pump Startup.................................................................. 314 Parts Identification.................................................................... 315 Disassembly And Assembly................................................................ 316 HYDRAULIC PUMP (HIGH FLOW).................................................................. 317 Description............................................................................. 317 Pump Test At Quick Couplers............................................................. 317 Direct Pump Test (Standard Section)..................................................... 318 Direct Pump Test (Charge Section)....................................................... 319 Direct Pump Test (High Flow Section).................................................... 321 High Flow Relief Valve Adjustment....................................................... 323 High Flow Relief Valve Removal And Installation......................................... 324 Solenoid Removal And Installation....................................................... 325 Removal And Installation................................................................ 326 Hydraulic Pump Startup.................................................................. 328 Parts Identification.................................................................... 329 Disassembly And Assembly................................................................ 330 HYDRAULIC / HYDROSTATIC FILTERS............................................................. 331 Description............................................................................. 331 Housing Removal And Installation........................................................ 331 HYDRAULIC FLUID RESERVOIR................................................................... 333 Description............................................................................. 333 Removal And Installation................................................................ 333 Hydraulic Fluid Screen.................................................................. 334 OIL COOLER.................................................................................. 335 Description............................................................................. 335 Removal And Installation................................................................ 336 BUCKET POSITION VALVE....................................................................... 337 Description............................................................................. 337 Solenoid Removal And Installation....................................................... 337 Solenoid Testing........................................................................ 340 Removal And Installation................................................................ 340 Disassembly And Assembly................................................................ 343 REAR AUXILIARY DIVERTER VALVE............................................................... 345 Description............................................................................. 345 Solenoid Testing........................................................................ 345 Removal And Installation................................................................ 346 Disassembly And Assembly................................................................ 347 BOB-TACH (POWER) BLOCK (S/N ATF611001 - ATF615134).......................................... 353 Description............................................................................. 353 Removal And Installation................................................................ 353 Disassembly And Assembly................................................................ 355 BOB-TACH (POWER) BLOCK (S/N ATF615135 & ABOVE).............................................. 363 Description............................................................................. 363 Testing Relief Valve.................................................................... 364 Removal And Installation................................................................ 366 Disassembly And Assembly................................................................ 368 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK..................................................... 373 Description............................................................................. 373 Removal And Installation................................................................ 374 Disassembly And Assembly (FFI/FI)....................................................... 374 Disassembly And Assembly (FFH/FH)....................................................... 376 HYDROSTATIC SYSTEM.............................................................................. 379 HYDROSTATIC SYSTEM INFORMATION.............................................................. 381 Description............................................................................. 381 Troubleshooting......................................................................... 382 HYDROSTATIC DRIVE MOTOR..................................................................... 383 Description............................................................................. 383 Removing And Replacing Fluid............................................................ 383 Removal And Installation................................................................ 384 Parts Identification.................................................................... 386 Disassembly And Assembly................................................................ 388 HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N ATF611001 - ATF611599)............................. 401 Description............................................................................. 401 Removing And Replacing Fluid............................................................ 401 Removal And Installation................................................................ 402 Parts Identification.................................................................... 404 Disassembly And Assembly................................................................ 406 HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (S/N ATF611600 & ABOVE)................................. 419 Description............................................................................. 419 Removing And Replacing Fluid............................................................ 419 Removal And Installation................................................................ 420 Parts Identification.................................................................... 422 Disassembly And Assembly................................................................ 424 CHARGE PRESSURE............................................................................. 437 Description............................................................................. 437 Testing................................................................................. 437 Sender Removal And Installation......................................................... 439 Adjusting............................................................................... 440 HYDROSTATIC PUMP............................................................................ 443 Description............................................................................. 443 Removal And Installation................................................................ 444 Hydrostatic Pump Startup................................................................ 445 Replenishing / High Pressure Relief Valve Removal And Installation...................... 445 Parts Identification (Left Half)........................................................ 446 Parts Identification (Right Half)....................................................... 447 Disassembly............................................................................. 448 Assembly................................................................................ 455 HYDROSTATIC PUMP (SJC)...................................................................... 463 Description............................................................................. 463 Hydraulic Controller Removal And Installation........................................... 464 Removal And Installation................................................................ 466 Hydrostatic Pump Startup................................................................ 468 Parts Identification.................................................................... 469 High Pressure Relief And Bypass Valve................................................... 470 Charge Relief Valve..................................................................... 471 Disassembly............................................................................. 472 Inspection.............................................................................. 481 Assembly................................................................................ 485 Mechanical Neutral Adjustment........................................................... 495 Hydraulic Controller Neutral Adjustment................................................. 498 DRIVE BELT.................................................................................. 501 Belt Adjustment......................................................................... 501 Stop Adjustment......................................................................... 501 Belt Replacement........................................................................ 502 Tensioner Pulley Removal And Installation............................................... 504 Tensioner Pulley Disassembly And Assembly............................................... 504 TWO-SPEED / BRAKE VALVE (S/N ATF611001 - ATF611599)......................................... 507 Description............................................................................. 507 Valve Block Removal And Installation.................................................... 508 Valve Block Disassembly And Assembly.................................................... 510 TWO-SPEED / BRAKE VALVE (S/N ATF611600 & ABOVE)............................................. 513 Description............................................................................. 513 Valve Block Removal And Installation.................................................... 514 Valve Block Disassembly And Assembly.................................................... 516 DRAIN MANIFOLD.............................................................................. 519 Description............................................................................. 519 Drain Manifold Removal And Installation................................................. 519 DRIVE SYSTEM.................................................................................... 521 BRAKE....................................................................................... 523 Description............................................................................. 523 Block Removal And Installation.......................................................... 523 Block Disassembly And Assembly.......................................................... 524 BRAKE (TWO-SPEED)........................................................................... 527 Description............................................................................. 527 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED).............................................. 529 Description............................................................................. 529 Checking Tension........................................................................ 530 Adjusting Tension....................................................................... 531 Track Removal And Installation.......................................................... 532 Idler (Front) Removal And Installation.................................................. 534 Track Tensioner Disassembly And Assembly................................................ 537 Idler (Rear) Removal And Installation................................................... 539 Roller Removal And Installation......................................................... 539 Sprocket Removal And Installation (Single Speed)........................................ 540 Sprocket Removal And Installation (Two Speed)........................................... 540 Track Housing Removal And Installation.................................................. 541 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION).......................................... 543 Description............................................................................. 543 Checking Tension........................................................................ 544 Adjusting Tension....................................................................... 545 Track Removal And Installation.......................................................... 546 Idler (Front) Removal And Installation.................................................. 548 Track Tensioner Disassembly And Assembly................................................ 551 Idler (Rear) Removal And Installation................................................... 553 Roller Removal And Installation......................................................... 553 Leaf Spring Removal And Installation.................................................... 554 Sprocket Removal And Installation (Single Speed)........................................ 555 Sprocket Removal And Installation (Two Speed)........................................... 555 Track Housing Removal And Installation.................................................. 556 TRACK MAINTENANCE........................................................................... 557 Track Damage Identification............................................................. 557 MAINFRAME....................................................................................... 569 SEAT BAR.................................................................................... 573 Description............................................................................. 573 Removal And Installation................................................................ 573 Disassembly And Assembly................................................................ 574 Compression Spring Disassembly And Assembly............................................. 575 OPERATOR CAB................................................................................ 577 Gas Spring Removal And Installation..................................................... 577 Gas Spring Bracket Disassembly And Assembly............................................. 578 Removal And Installation................................................................ 578 OPERATOR SEAT (SUSPENSION).................................................................. 581 Removal And Installation................................................................ 581 Slide Rail Removal And Installation..................................................... 581 Seat Belt Removal And Installation...................................................... 582 Lower Cushion Removal................................................................... 582 Lower Cushion Installation.............................................................. 583 Back Cushion Removal And Installation................................................... 583 Shock Removal And Installation.......................................................... 584 3-Point Seat Belt Removal And Installation.............................................. 584 BOB-TACH (HAND LEVER)....................................................................... 587 Description............................................................................. 587 Removal And Installation................................................................ 587 Lever And Wedge Disassembly And Assembly................................................ 589 Pivot Pin Bushing And Seal Removal And Installation..................................... 591 BOB-TACH (POWER)............................................................................ 593 Description............................................................................. 593 Removal And Installation................................................................ 593 Lever And Wedge Disassembly And Assembly................................................ 596 Pivot Pin Bushing And Seal Removal And Installation..................................... 598 LIFT ARMS................................................................................... 599 Stabilizer Bar Removal And Installation................................................. 599 Link Removal And Installation........................................................... 600 Removal And Installation................................................................ 601 REAR GRILLE................................................................................. 605 Removing................................................................................ 605 Installing.............................................................................. 605 REAR DOOR (TAILGATE)........................................................................ 607 Removal And Installation................................................................ 607 Striker Removal And Installation........................................................ 608 Striker Disassembly And Assembly........................................................ 608 Striker (Adjusting)..................................................................... 608 Latch Removal And Installation (Earlier Models)......................................... 609 Latch Removal And Installation (Later Models)........................................... 610 FUEL TANK................................................................................... 611 Removal And Installation................................................................ 611 Fuel Level Sender Removal And Installation.............................................. 613 Fuel Fill Screen Removal And Installation............................................... 613 CONTROL PEDALS AND LINKAGES................................................................. 615 Description............................................................................. 615 Pedal Removal And Installation.......................................................... 615 Linkage Removal And Installation........................................................ 617 Pedal (Adjusting)....................................................................... 619 Floor Pan Removal And Installation...................................................... 620 CONTROL PEDALS AND LINKAGES (ACS)........................................................... 621 Description............................................................................. 621 Pedal Removal And Installation.......................................................... 621 Linkage Removal And Installation........................................................ 622 Pedal (Adjusting)....................................................................... 622 Floor Pan Removal And Installation...................................................... 623 CONTROL PANEL............................................................................... 625 Description............................................................................. 625 Removal And Installation................................................................ 626 Disassembly And Assembly................................................................ 627 Linkage Removal And Installation........................................................ 629 Pintle Arm Disassembly And Assembly..................................................... 633 Linkage Neutral (Adjusting)............................................................. 634 Linkage Travel (Adjusting).............................................................. 638 Shock Removal And Installation.......................................................... 642 CONTROL PANEL (SJC)......................................................................... 643 Description............................................................................. 643 Removal And Installation................................................................ 643 CONTROL HANDLE / LEVER...................................................................... 645 Description............................................................................. 645 Lever Removal And Installation.......................................................... 645 Boot Removal And Installation........................................................... 646 CONTROL HANDLE / LEVER (ACS)................................................................ 647 Description............................................................................. 647 Handle Sensor Removal And Installation.................................................. 647 Handle Removal And Installation......................................................... 650 Handle Disassembly And Assembly......................................................... 651 Lever Removal And Installation.......................................................... 651 Boot Removal And Installation........................................................... 652 CONTROL HANDLE / LEVER (SJC)................................................................ 653 Description............................................................................. 653 Joystick Testing........................................................................ 653 Joystick Removal And Installation....................................................... 654 ACCESS PANEL (INSIDE)....................................................................... 655 Removal And Installation (Left)......................................................... 655 Removal And Installation (Right)........................................................ 655 ACCESS PANEL (INSIDE) (SJC)................................................................. 657 Removal And Installation (Left)......................................................... 657 Removal And Installation (Right)........................................................ 657 WINDOW (REAR)............................................................................... 659 Rear Window Identification.............................................................. 659 Removal And Installation (Latches)...................................................... 659 Disassembly And Assembly (Latches)...................................................... 660 Removal (Rubber Cord)................................................................... 661 Installation (Rubber Cord).............................................................. 662 WINDOW (TOP)................................................................................ 665 Removal And Installation................................................................ 665 WINDOW (SIDE)............................................................................... 667 Removal And Installation................................................................ 667 CAB DOOR.................................................................................... 669 Description............................................................................. 669 Removal And Installation................................................................ 669 Disassembly And Assembly................................................................ 670 Aligning................................................................................ 671 Adjusting............................................................................... 672 Checking Operation...................................................................... 672 ARMREST..................................................................................... 673 Description............................................................................. 673 Removal And Installation................................................................ 673 Disassembly And Assembly................................................................ 674 LEFT SIDE LOWER PANEL....................................................................... 677 Removal And Installation................................................................ 677 Disassembly And Assembly................................................................ 679 RIGHT SIDE LOWER PANEL...................................................................... 681 Removal And Installation................................................................ 681 Disassembly And Assembly................................................................ 682 HEADLINER................................................................................... 685 Removal And Installation................................................................ 685 ELECTRICAL SYSTEM AND ANALYSIS.................................................................. 687 ELECTRICAL SCHEMATIC ....................................................................... 693 ELECTRICAL SYSTEM INFORMATION............................................................... 889 Glossary Of Electrical Symbols.......................................................... 889 Standard Cab Harness Connectors......................................................... 892 Deluxe Cab Harness Connectors........................................................... 893 Mainframe Harness Connectors............................................................ 894 Engine Harness Connectors............................................................... 895 Description............................................................................. 896 Troubleshooting......................................................................... 897 Fuse And Relay Location / Identification................................................ 898 Solenoid Testing........................................................................ 901 BATTERY..................................................................................... 903 Removal And Installation................................................................ 903 Servicing............................................................................... 904 Using A Booster Battery (Jump Starting)................................................. 905 ALTERNATOR.................................................................................. 907 Belt Adjustment......................................................................... 907 Belt Replacement........................................................................ 907 Charging System Inspection.............................................................. 908 Alternator Voltage Testing.............................................................. 909 Low Voltage Testing..................................................................... 909 High Voltage Testing.................................................................... 910 Removal And Installation................................................................ 911 Parts Identification.................................................................... 913 STARTER..................................................................................... 915 Testing................................................................................. 915 Removal And Installation................................................................ 915 Parts Identification.................................................................... 916 INSTRUMENT PANELS........................................................................... 917 Left Panel.............................................................................. 917 Display Screen.......................................................................... 919 Right Panel (Standard Key Panel)........................................................ 920 Right Panel (Keyless Start Panel)....................................................... 921 Right Panel (Deluxe Instrumentation Panel).............................................. 922 Left Switch Panel....................................................................... 924 Right Switch Panel...................................................................... 924 Left Side Lower Panel................................................................... 925 Right Side Lower Panel.................................................................. 925 Left Panel Removal And Installation..................................................... 926 Right Panel (Standard Key Panel) Removal And Installation............................... 926 Right Panel (Keyless Start Panel) Removal And Installation.............................. 927 Right Panel (Deluxe Instrumentation Panel) Removal And Installation..................... 927 Key Switch Disassembly And Assembly..................................................... 928 Alarm Disassembly And Assembly.......................................................... 928 Left Switch Panel Removal And Installation.............................................. 929 Right Switch Panel Removal And Installation............................................. 929 LIGHTS...................................................................................... 931 Front Removal And Installation.......................................................... 931 Rear Removal And Installation........................................................... 932 Cab Light Removal And Installation (Early Models)....................................... 932 Cab Light Removal And Installation (Later Models)....................................... 933 BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY).................................................. 935 Description............................................................................. 935 Connector Identification................................................................ 936 Removal And Installation................................................................ 942 BOBCAT CONTROLLER (ACS)..................................................................... 943 Description............................................................................. 943 Connector And Wire Identification....................................................... 944 Removal And Installation................................................................ 945 BOBCAT CONTROLLER (SJC) (DRIVE)............................................................. 947 Description............................................................................. 947 Connector Identification................................................................ 948 Removal And Installation................................................................ 950 ENGINE CONTROL UNIT (ECU)................................................................... 951 Description............................................................................. 951 Cleaning................................................................................ 952 Removal And Installation................................................................ 953 DIAGNOSTIC SERVICE CODES.................................................................... 955 Viewing Service Codes................................................................... 955 Service Codes List...................................................................... 956 DIAGMASTER DIAGNOSTIC TROUBLE CODES (DCT)................................................... 963 Viewing Trouble Codes................................................................... 963 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)..................................................... 965 Description............................................................................. 965 Operation............................................................................... 965 Inspecting The BICS™ (Engine STOPPED - Key ON).......................................... 966 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON).... 966 Inspecting The Seat Bar Sensor (Engine RUNNING)......................................... 966 Inspecting The Traction Lock And Parking Brake (Engine RUNNING)......................... 966 Inspecting The Lift Arm Bypass Control.................................................. 966 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)........................ 966 Troubleshooting......................................................................... 967 SEAT BAR SENSOR............................................................................. 969 Description............................................................................. 969 Troubleshooting......................................................................... 969 Testing................................................................................. 970 Removal And Installation................................................................ 971 Bobcat Interlock Control System (BICS™) Circuit Test.................................... 974 TRACTION LOCK............................................................................... 977 Description............................................................................. 977 Troubleshooting......................................................................... 978 Inspecting.............................................................................. 979 CONTROL SYSTEM (ACS)........................................................................ 981 Description............................................................................. 981 Troubleshooting......................................................................... 982 Handle Sensor Connector Disassembly And Assembly........................................ 983 Switch Handle Removal................................................................... 984 Switch Handle Installation.............................................................. 986 Actuator Connector Disassembly And Assembly............................................. 989 Handle Lock Solenoid Removal And Installation........................................... 990 Handle Lock Solenoid Disassembly And Assembly........................................... 990 Foot Sensor Removal And Installation.................................................... 991 Foot Sensor Disassembly And Assembly.................................................... 992 Foot Sensor Lock Solenoid Removal And Installation...................................... 992 ELECTRICAL / HYDRAULIC CONTROLS............................................................. 993 Identification Chart.................................................................... 993 Description............................................................................. 994 Identification Chart ACD Group 0........................................................ 995 Identification Chart ACD Group 1........................................................ 996 Identification Chart ACD Group 2........................................................ 997 Identification Chart ACD Group 3........................................................ 998 ELECTRICAL / HYDRAULIC CONTROLS (ACS)....................................................... 999 Identification Chart.................................................................... 999 Description.............................................................................1000 Identification Chart ACD Group 0........................................................1001 Identification Chart ACD Group 1........................................................1002 Identification Chart ACD Group 2........................................................1003 Identification Chart ACD Group 3........................................................1004 ELECTRICAL / HYDRAULIC CONTROLS (SJC).......................................................1005 Identification Chart....................................................................1005 Description.............................................................................1006 Identification Chart ACD Group 0........................................................1007 Identification Chart ACD Group 1........................................................1008 Identification Chart ACD Group 2........................................................1009 Identification Chart ACD Group 3........................................................1010 SERVICE PC (LAPTOP COMPUTER)................................................................1011 Connecting Remote Start Tool............................................................1011 Connecting Remote Start Tool (Service Tool).............................................1011 Connecting Diagmaster (Service Tool)....................................................1012 Connecting Remote Parked Regeneration Kit...............................................1012 CALIBRATION.................................................................................1013 Description.............................................................................1013 Actuator Testing........................................................................1013 Lift And Tilt Calibration (SJC).........................................................1016 Hydrostatic Pump Calibration (SJC)......................................................1018 Lift And Tilt Calibration (ACS).........................................................1023 STEERING DRIFT COMPENSATION (OPERATOR MODE).................................................1025 Description.............................................................................1025 Operation...............................................................................1025 STEERING DRIFT COMPENSATION (SERVICE MODE)..................................................1027 Description.............................................................................1027 Operation...............................................................................1027 CONTROL PANEL SETUP.........................................................................1029 Right Panel Setup (Deluxe Instrumentation Panel)........................................1029 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)...............................................1033 Password Description....................................................................1033 Changing The Owner Password.............................................................1033 Changing The User Passwords.............................................................1034 Password Lockout Feature................................................................1034 PASSWORD SETUP (KEYLESS START PANEL)........................................................1035 Password Description....................................................................1035 Changing The Owner Password.............................................................1035 Password Lockout Feature................................................................1035 MAINTENANCE CLOCK...........................................................................1037 Description.............................................................................1037 Setup...................................................................................1038 Reset...................................................................................1041 BACK-UP ALARM SYSTEM........................................................................1043 Description.............................................................................1043 Inspecting..............................................................................1043 Adjusting Switch Position...............................................................1044 Troubleshooting (Standard And ACS)......................................................1045 Troubleshooting (Joystick)..............................................................1046 Alarm Removal And Installation..........................................................1047 Switch Removal And Installation.........................................................1047 FRONT HORN..................................................................................1049 Removal And Installation................................................................1049 Troubleshooting.........................................................................1050 Troubleshooting (Joystick)..............................................................1051 ENGINE SERVICE..................................................................................1053 ENGINE INFORMATION..........................................................................1057 Description.............................................................................1057 Specifications..........................................................................1058 Sensor Location.........................................................................1061 Torque Values...........................................................................1064 Troubleshooting.........................................................................1065 Engine Removal And Installation.........................................................1066 Engine Mount Replacement................................................................1079 Compression - Testing...................................................................1081 ENGINE SPEED CONTROL (HAND).................................................................1085 Removal And Installation................................................................1085 ENGINE SPEED CONTROL (FOOT).................................................................1087 Removal And Installation................................................................1087 Disassembly And Assembly................................................................1088 DIESEL PARTICULATE FILTER (DPF) SYSTEM......................................................1091 Description.............................................................................1091 Removal And Installation................................................................1092 DPF Regeneration........................................................................1095 DPF Regeneration Table..................................................................1095 Operation (Standard Switch).............................................................1096 Operation (Optional Inhibit Switch Kit).................................................1097 Operation (Optional Remote Parked Regeneration Kit).....................................1098 Remote Parked Regeneration (Level 3)....................................................1098 DPF Service Regeneration (Level 4)......................................................1100 DPF Cleaning (Level 5)..................................................................1103 AIR CLEANER.................................................................................1105 Housing Removal And Installation........................................................1105 ENGINE COOLING SYSTEM (EARLIER MODELS)......................................................1107 Radiator Removal And Installation.......................................................1107 Hydraulic Fan Description...............................................................1108 Fan Duct Removal And Installation.......................................................1109 Hydraulic Fan Motor Assembly Removal And Installation...................................1109 Hydraulic Fan Motor Removal And Installation............................................1110 Hydraulic Fan Motor Disassembly And Assembly............................................1111 Blower Housing Removal And Installation.................................................1113 Water Pump Removal And Installation.....................................................1113 Water Pump Disassembly And Assembly.....................................................1114 Thermostat Housing Removal And Installation.............................................1114 Thermostat - Testing....................................................................1115 ENGINE COOLING SYSTEM (LATER MODELS)........................................................1117 Radiator Removal And Installation.......................................................1117 Hydraulic Fan Description...............................................................1118 Fan Duct Removal And Installation.......................................................1119 Hydraulic Fan Motor Assembly Removal And Installation...................................1119 Hydraulic Fan Motor Removal And Installation............................................1120 Hydraulic Fan Motor Disassembly And Assembly............................................1122 Blower Housing Removal And Installation.................................................1127 Water Pump Removal And Installation.....................................................1128 Water Pump Disassembly And Assembly.....................................................1128 Thermostat Housing Removal And Installation.............................................1129 Thermostat - Testing....................................................................1129 LUBRICATION SYSTEM..........................................................................1131 Oil Pan Removal And Installation........................................................1131 Oil Pump Removal And Installation.......................................................1132 Oil Pump Inspection.....................................................................1132 Oil Filter Cooler Removal And Installation..............................................1134 Engine Oil Pressure - Testing...........................................................1135 Crankcase Ventilation Filter Removal And Installation...................................1136 FUEL SYSTEM.................................................................................1137 Supply Pump Removal.....................................................................1137 Supply Pump Installation................................................................1140 Supply Pump Difference Learning.........................................................1142 Fuel Rail Assembly Removal And Installation.............................................1144 Supply Pump - Timing....................................................................1145 Fuel Injector Removal And Installation..................................................1146 Injector Correction.....................................................................1150 CYLINDER HEAD...............................................................................1151 Intake Air Heater - Testing.............................................................1151 Intake Air Heater Removal And Installation..............................................1151 Valve Clearance Adjustment..............................................................1152 Valve Timing - Checking.................................................................1154 Cylinder Head Removal And Installation..................................................1155 Cylinder Head Disassembly And Assembly..................................................1157 Cylinder Head - Servicing...............................................................1158 Cylinder Head Top Clearance.............................................................1158 Valve Guide - Servicing.................................................................1159 Reconditioning The Valve And Valve Seat.................................................1161 Valve Spring............................................................................1163 Valve Tappets...........................................................................1164 Rocker Arm And Shaft - Measuring........................................................1165 Push Rod Alignment - Measuring..........................................................1165 CRANKSHAFT AND PISTONS......................................................................1167 Piston And Connecting Rod Removal And Installation......................................1167 Piston And Connecting Rod - Servicing...................................................1169 Cylinder Bore - Measuring...............................................................1173 Connecting Rod Alignment................................................................1174 Crankshaft Gear Removal And Installation................................................1174 Crankshaft And Bearings Removal.........................................................1175 Crankshaft And Bearings Installation....................................................1177 Crankshaft And Bearings - Servicing.....................................................1179 CRANKSHAFT POSITION SENSOR..................................................................1185 Description.............................................................................1185 Removal And Installation................................................................1185 Adjusting...............................................................................1186 CAMSHAFT AND TIMING GEARS...................................................................1189 Timing Gearcase Cover Removal And Installation..........................................1189 Timing Gears Backlash - Measuring.......................................................1190 Idler Gear And Camshaft Removal And Installation........................................1190 Camshaft - Servicing....................................................................1191 Idler Gear And Shaft - Servicing........................................................1193 TURBOCHARGER................................................................................1197 Description.............................................................................1197 Removal And Installation................................................................1198 Testing.................................................................................1200 EGR Cooler Testing......................................................................1201 FLYWHEEL AND HOUSING........................................................................1203 Flywheel Removal And Installation.......................................................1203 Ring Gear Removal And Installation......................................................1203 Housing Removal And Installation........................................................1204 EXHAUST GAS RECIRCULATION (EGR) SYSTEM......................................................1205 Description.............................................................................1205 Testing.................................................................................1206 Removal And Installation................................................................1208 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)................................................1209 AIR CONDITIONING SYSTEM FLOW................................................................1211 Description.............................................................................1211 Chart...................................................................................1212 Components..............................................................................1213 Safety Equipment........................................................................1216 REGULAR MAINTENANCE.........................................................................1217 Filters.................................................................................1217 Compressor Drive Belt Adjustment........................................................1218 Compressor Drive Belt Replacement.......................................................1218 Condenser...............................................................................1218 Air Conditioning Lubrication............................................................1218 Air Conditioning Service Chart..........................................................1219 Evaporator / Heater Coil................................................................1220 TROUBLESHOOTING.............................................................................1223 Blower Motor Does Not Operate...........................................................1223 Blower Motor Operates Normally, But Air Flow Is Insufficient............................1223 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal..............1223 The Compressor Does Not Operate At All, Or Operates Improperly..........................1223 Gauge Pressure Related Troubleshooting..................................................1224 Troubleshooting Tree....................................................................1226 Temperature / Pressure Chart............................................................1229 Poor A/C Performance....................................................................1231 HVAC Repair And Leaks...................................................................1232 Electrical System.......................................................................1233 Engine Coolant Bypassing The Heater Valve...............................................1239 Heater Valve Not Opening Or Closing.....................................................1240 SYSTEM CHARGING AND RECLAMATION.............................................................1243 Refrigerant Identification..............................................................1243 Reclamation And Charging With Recovery / Charging Unit..................................1244 COMPRESSOR..................................................................................1247 Removal And Installation................................................................1247 Oil.....................................................................................1249 Oil Check...............................................................................1250 CONDENSER...................................................................................1251 Removal And Installation................................................................1251 RECEIVER / DRIER............................................................................1253 Receiver / Drier Removal And Installation...............................................1253 Pressure Relief Valve Removal And Installation..........................................1254 Pressure Switch Removal And Installation................................................1255 Schrader® Valve Removal And Installation................................................1256 EVAPORATOR / HEATER UNIT....................................................................1257 Removal And Installation................................................................1257 THERMOSTAT..................................................................................1259 Description.............................................................................1259 Removal And Installation................................................................1260 EXPANSION VALVE.............................................................................1261 Removal And Installation................................................................1261 EVAPORATOR COIL.............................................................................1263 Removal And Installation................................................................1263 HEATER COIL.................................................................................1265 Removal And Installation................................................................1265 BLOWER FAN..................................................................................1267 Removal And Installation................................................................1267 Disassembly And Assembly................................................................1267 HEATER VALVE................................................................................1271 Removal And Installation................................................................1271 EVAPORATOR / HEATER COVER...................................................................1273 Removing................................................................................1273 Installing..............................................................................1273 SPECIFICATIONS..................................................................................1275 (T750) LOADER SPECIFICATIONS................................................................1277 Machine Dimensions......................................................................1277 Performance.............................................................................1278 Engine..................................................................................1278 Drive System............................................................................1279 Controls................................................................................1279 Hydraulic System........................................................................1280 Electrical System.......................................................................1281 Capacities..............................................................................1281 Tracks..................................................................................1282 Ground Pressure.........................................................................1282 TECHINCAL SERVICE GUIDE SPECIFICATIONS......................................................1283 Engine..................................................................................1283 Engine Torques..........................................................................1283 Cooling System..........................................................................1283 Loader Torques..........................................................................1284 Hydraulic / Hydrostatic System..........................................................1284 Fuel Consumption........................................................................1284 TORQUE SPECIFICATIONS FOR BOLTS.............................................................1285 Torque For General SAE Bolts............................................................1285 Torque For General Metric Bolts.........................................................1286 HYDRAULIC CONNECTION SPECIFICATIONS.........................................................1287 Straight Thread O-ring Fitting..........................................................1287 Flare Fitting...........................................................................1288 Tubelines And Hoses.....................................................................1288 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS................................................1289 Specifications..........................................................................1289 CONVERSIONS.................................................................................1291 Decimal And Millimeter Equivalent Chart.................................................1291 U.S. To Metric Conversion Chart.........................................................1291 SERVICE TOOLS REQUIRED......................................................................1293 Remote Start Tools......................................................................1293 Hydraulic Tools.........................................................................1294 Mainframe And Drive Tools...............................................................1297 Electrical Tools........................................................................1300 Engine Tools............................................................................1301 HVAC Tools..............................................................................1306 ALPHABETICAL INDEX..............................................................................1307
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