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Bobcat T750 Skid-Steer Loader Service Manual SN AT5T11001 & Above – PDF DOWNLOAD
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Bobcat T750 Skid-Steer Loader Service Manual SN AT5T11001 & Above – PDF DOWNLOAD
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Description
Bobcat T750 Skid-Steer Loader Service Manual SN AT5T11001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat T750 Skid-Steer Loader Service Manual SN AT5T11001 & Above – PDF DOWNLOAD
Language : English
Pages : 1206
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Bobcat T750 Skid-Steer Loader Service Manual SN AT5T11001 & 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 Skid-Steer Loader Service Manual SN AT5T11001 & 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...................................................................................... 26 Removing........................................................................................ 27 OPERATOR CAB........................................................................................ 29 Description..................................................................................... 29 Raising......................................................................................... 30 Lowering........................................................................................ 31 Cab Door Sensor................................................................................. 32 Special Applications Kit........................................................................ 33 Special Applications Kit Inspection And Maintenance............................................. 33 Forestry Door And Window Kit.................................................................... 34 Forestry Door And Window Kit Inspection And Maintenance......................................... 34 TRANSPORTING THE LOADER ON A TRAILER................................................................ 35 Loading And Unloading........................................................................... 35 Fastening....................................................................................... 35 TOWING THE LOADER................................................................................... 37 Procedure....................................................................................... 37 REMOTE START TOOL KIT - MEL1563..................................................................... 39 Remote Start Tool - MEL1563..................................................................... 39 Service Tool Harness Communicator - MEL1566..................................................... 41 Remote Start Procedure.......................................................................... 41 REMOTE START TOOL (SERVICE TOOL) KIT - 7217666...................................................... 45 Description..................................................................................... 45 Remote Start Tool (Service Tool) - 7022042...................................................... 46 Loader Service Tool Harness - 6689747........................................................... 47 Computer Service Tool Harness - 6689746......................................................... 48 Remote Start Procedure.......................................................................... 49 SERVICE SCHEDULE.................................................................................... 53 Maintenance Intervals........................................................................... 53 ENGINE AIR CLEANER.................................................................................. 55 Replacing Filters............................................................................... 55 ENGINE COOLING SYSTEM............................................................................... 57 Maintenance Platform............................................................................ 57 Cleaning........................................................................................ 57 Checking And Adding Coolant..................................................................... 60 Removing And Replacing Coolant.................................................................. 61 FUEL SYSTEM......................................................................................... 63 Fuel Specifications............................................................................. 63 Biodiesel Blend Fuel............................................................................ 63 Filling The Fuel Tank........................................................................... 64 Fuel Filter..................................................................................... 65 Removing Air From The Fuel System............................................................... 66 DIESEL EXHAUST FLUID (DEF) / ADBLUE® SYSTEM......................................................... 67 Description..................................................................................... 67 Filling The DEF / AdBlue® Tank.................................................................. 67 ENGINE LUBRICATION SYSTEM........................................................................... 69 Checking And Adding Engine Oil.................................................................. 69 Engine Oil Chart................................................................................ 69 Removing And Replacing Oil And Filter........................................................... 70 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................................................................ 78 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.............................................................. 86 PIVOT PINS.......................................................................................... 87 Inspection And Maintenance...................................................................... 87 LOADER STORAGE AND RETURN TO SERVICE................................................................ 89 Storage......................................................................................... 89 Return To Service............................................................................... 89 STOPPING THE ENGINE AND LEAVING THE LOADER.......................................................... 91 Procedure....................................................................................... 91 EMERGENCY EXIT...................................................................................... 93 Rear Window Identification...................................................................... 93 Rear Window Removal (Latches)................................................................... 93 Rear Window Removal (Rubber Cord)............................................................... 93 External Access (Rear Window With Latches)...................................................... 94 External Access (Rear Window With Rubber Cord).................................................. 94 Front Door...................................................................................... 94 SEAT BELT........................................................................................... 97 Inspection And Maintenance...................................................................... 97 HYDRAULIC SYSTEM........................................................................................ 99 HYDRAULIC / HYDROSTATIC SCHEMATICS.................................................................. 105 HYDRAULIC SYSTEM INFORMATION........................................................................ 117 Glossary Of Hydraulic / Hydrostatic Symbols..................................................... 117 Troubleshooting................................................................................. 121 CYLINDER (LIFT)..................................................................................... 123 Testing......................................................................................... 123 Removal And Installation........................................................................ 124 Parts Identification............................................................................ 128 Disassembly..................................................................................... 129 Assembly........................................................................................ 130 CYLINDER (TILT)..................................................................................... 135 Testing......................................................................................... 135 Removal And Installation........................................................................ 136 Base End Pivot Pin Removal And Installation..................................................... 138 Parts Identification............................................................................ 139 Disassembly..................................................................................... 140 Assembly........................................................................................ 142 CYLINDER (BOB-TACH)................................................................................. 145 Testing......................................................................................... 145 Removal And Installation........................................................................ 146 Parts Identification............................................................................ 147 Disassembly..................................................................................... 148 Assembly........................................................................................ 149 MAIN RELIEF VALVE................................................................................... 153 Description..................................................................................... 153 Testing......................................................................................... 154 Main Relief Valve Adjustment.................................................................... 156 Main Relief Valve Removal And Installation...................................................... 156 Auxiliary Relief Valve Adjustment............................................................... 157 Auxiliary Relief Valve Removal And Installation................................................. 158 HYDRAULIC CONTROL VALVE (STANDARD).................................................................. 159 Description..................................................................................... 159 Removal And Installation........................................................................ 160 Mount Bracket Removal And Installation.......................................................... 164 Identification Chart............................................................................ 165 Lift Load Check Valve Removal And Installation.................................................. 166 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 167 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 168 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 168 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 169 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 169 Port Relief Valve Removal And Installation...................................................... 170 Plug Removal And Installation................................................................... 172 Rubber Boot Removal And Installation............................................................ 173 End Cap Block Removal And Installation.......................................................... 173 Lift Spool And Detent Removal................................................................... 174 Lift Spool And Detent Disassembly............................................................... 176 Lift Spool And Detent Assembly.................................................................. 178 Lift Spool And Detent Installation.............................................................. 180 Tilt Spool Removal And Installation............................................................. 182 Tilt Spool Disassembly And Assembly............................................................. 183 Auxiliary Spool Removal And Installation........................................................ 184 Auxiliary Solenoid Removal And Installation..................................................... 185 Solenoid Removal And Installation............................................................... 186 Lock Valve Removal And Installation............................................................. 187 Lift Arm Bypass Orifice Removal And Installation................................................ 189 Main Relief Valve Removal And Installation...................................................... 189 Auxiliary Relief Valve Removal And Installation................................................. 190 Check Valve Removal And Installation............................................................ 190 HYDRAULIC CONTROL VALVE (ACS) OR (SJC).............................................................. 193 Description..................................................................................... 193 Removal And Installation........................................................................ 193 Actuator Removal And Installation (In Loader)................................................... 198 Actuator Removal And Installation (Out Of Loader)............................................... 199 Identification Chart............................................................................ 202 Mount Bracket Removal And Installation.......................................................... 203 Lift Load Check Valve Removal And Installation.................................................. 203 Load Check Valve Removal And Installation (Tilt And Auxiliary).................................. 204 Anti-Cavitation Valve Removal And Installation (Lift, Rod End).................................. 205 Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)................... 205 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)................... 206 Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End).................... 206 Port Relief Valve Removal And Installation...................................................... 207 Plug Removal And Installation................................................................... 209 End Cap Block Removal And Installation.......................................................... 210 Lift Spool Removal And Installation............................................................. 210 Lift Spool Disassembly And Assembly............................................................. 212 Tilt Spool Removal And Installation............................................................. 213 Auxiliary Spool Removal And Installation........................................................ 215 Auxiliary Solenoid Removal And Installation..................................................... 216 Solenoid Removal And Installation............................................................... 217 Lock Valve Removal And Installation............................................................. 218 Lift Arm Bypass Orifice Removal And Installation................................................ 220 Main Relief Valve Removal And Installation...................................................... 220 Auxiliary Relief Valve Removal And Installation................................................. 221 Check Valve Removal And Installation............................................................ 221 LIFT ARM BYPASS CONTROL VALVE....................................................................... 223 Description..................................................................................... 223 Testing......................................................................................... 223 Removal And Installation........................................................................ 224 Bracket Removal And Installation................................................................ 225 Disassembly And Assembly........................................................................ 225 HYDRAULIC PUMP...................................................................................... 227 Description..................................................................................... 227 Pump Test At Quick Couplers..................................................................... 227 Direct Pump Test (Standard Section)............................................................. 228 Direct Pump Test (Charge Section)............................................................... 230 Removal And Installation........................................................................ 232 Hydraulic Pump Startup.......................................................................... 234 Parts Identification............................................................................ 235 Disassembly And Assembly........................................................................ 236 HYDRAULIC PUMP (HIGH FLOW).......................................................................... 237 Description..................................................................................... 237 Pump Test At Quick Couplers..................................................................... 237 Direct Pump Test (Standard Section)............................................................. 238 Direct Pump Test (Charge Section)............................................................... 239 Direct Pump Test (High Flow Section)............................................................ 241 High Flow Relief Valve Adjustment............................................................... 243 High Flow Relief Valve Removal And Installation................................................. 244 Solenoid Removal And Installation............................................................... 245 Removal And Installation........................................................................ 246 Hydraulic Pump Startup.......................................................................... 248 Parts Identification............................................................................ 249 Disassembly And Assembly........................................................................ 250 HYDRAULIC / HYDROSTATIC FILTERS..................................................................... 251 Description..................................................................................... 251 Housing Removal And Installation................................................................ 251 HYDRAULIC FLUID RESERVOIR........................................................................... 253 Description..................................................................................... 253 Removal And Installation........................................................................ 253 Hydraulic Fluid Screen.......................................................................... 254 OIL COOLER.......................................................................................... 255 Description..................................................................................... 255 Removal And Installation........................................................................ 255 BUCKET POSITION VALVE............................................................................... 257 Description..................................................................................... 257 Solenoid Removal And Installation............................................................... 257 Solenoid Testing................................................................................ 259 Removal And Installation........................................................................ 259 Disassembly And Assembly........................................................................ 262 REAR AUXILIARY DIVERTER VALVE....................................................................... 263 Description..................................................................................... 263 Solenoid Testing................................................................................ 263 Removal And Installation........................................................................ 264 Disassembly And Assembly........................................................................ 265 BOB-TACH (POWER) BLOCK.............................................................................. 271 Description..................................................................................... 271 Testing Relief Valve............................................................................ 272 Removal And Installation........................................................................ 274 Disassembly And Assembly........................................................................ 276 FRONT AUXILIARY HYDRAULIC COUPLER BLOCK............................................................. 281 Description..................................................................................... 281 Removal And Installation........................................................................ 282 Disassembly And Assembly (FFI/FI)............................................................... 282 Disassembly And Assembly (FFH/FH)............................................................... 284 AUTOMATIC RIDE CONTROL.............................................................................. 287 Description..................................................................................... 287 Removal And Installation........................................................................ 288 Checking The Pressure In The Accumulator........................................................ 291 Adding Nitrogen To The Accumulator.............................................................. 293 HYDROSTATIC SYSTEM...................................................................................... 295 HYDROSTATIC SYSTEM INFORMATION...................................................................... 297 Description..................................................................................... 297 Troubleshooting................................................................................. 298 HYDROSTATIC DRIVE MOTOR............................................................................. 299 Description..................................................................................... 299 Removing And Replacing Fluid.................................................................... 299 Removal And Installation........................................................................ 300 Parts Identification............................................................................ 302 Disassembly And Assembly........................................................................ 304 HYDROSTATIC DRIVE MOTOR (TWO-SPEED)................................................................. 317 Description..................................................................................... 317 Removing And Replacing Fluid.................................................................... 317 Removal And Installation........................................................................ 318 Parts Identification............................................................................ 320 Disassembly And Assembly........................................................................ 322 HYDROSTATIC DRIVE MOTOR (LATER MODELS WITH EIGHT TRACK SPROCKET BOLTS).............................. 335 Description..................................................................................... 335 Removing And Replacing Fluid.................................................................... 335 Removal And Installation........................................................................ 336 Parts Identification (Single Speed)............................................................. 338 Parts Identification (Two-Speed)................................................................ 340 Disassembly And Assembly........................................................................ 342 CHARGE PRESSURE..................................................................................... 357 Description..................................................................................... 357 Testing......................................................................................... 358 Sender Removal And Installation................................................................. 359 Adjusting....................................................................................... 360 HYDROSTATIC PUMP.................................................................................... 363 Description..................................................................................... 363 Removal And Installation........................................................................ 364 Hydrostatic Pump Startup........................................................................ 365 Replenishing / High Pressure Relief Valve Removal And Installation.............................. 365 Parts Identification (Left Half)................................................................ 366 Parts Identification (Right Half)............................................................... 367 Disassembly..................................................................................... 368 Assembly........................................................................................ 375 HYDROSTATIC PUMP (SJC).............................................................................. 383 Description..................................................................................... 383 Hydraulic Controller Removal And Installation................................................... 384 Removal And Installation........................................................................ 386 Hydrostatic Pump Startup........................................................................ 388 Parts Identification............................................................................ 389 High Pressure Relief And Bypass Valve........................................................... 390 Charge Relief Valve............................................................................. 391 Disassembly..................................................................................... 392 Inspection...................................................................................... 401 Assembly........................................................................................ 405 Mechanical NEUTRAL Adjustment................................................................... 414 Hydraulic Controller NEUTRAL Adjustment......................................................... 417 DRIVE BELT.......................................................................................... 421 Belt Adjustment................................................................................. 421 Stop Adjustment................................................................................. 421 Belt Replacement................................................................................ 422 Tensioner Pulley Removal And Installation (Earlier Models)...................................... 424 Tensioner Pulley Disassembly And Assembly....................................................... 424 Tensioner Pulley Removal And Installation (Later Models)........................................ 425 Tensioner Pulley Disassembly And Assembly....................................................... 425 TWO-SPEED / BRAKE VALVE............................................................................. 427 Description..................................................................................... 427 Valve Block Removal And Installation............................................................ 428 Valve Block Disassembly And Assembly............................................................ 430 DRAIN MANIFOLD...................................................................................... 433 Description..................................................................................... 433 Drain Manifold Removal And Installation......................................................... 433 DRIVE SYSTEM............................................................................................ 435 BRAKE............................................................................................... 437 Description..................................................................................... 437 Block Removal And Installation.................................................................. 437 Block Disassembly And Assembly.................................................................. 438 BRAKE (TWO-SPEED)................................................................................... 441 Description..................................................................................... 441 TRACK UNDERCARRIAGE COMPONENTS (SOLID-MOUNTED)...................................................... 443 Description..................................................................................... 443 Checking (Solid-Mounted Undercarriage).......................................................... 445 Adjusting (Solid-Mounted Undercarriage) (Earlier Models With Two Track Tension Fittings)........ 446 Adjusting (Solid-Mounted Undercarriage) (Later Models With One Track Tension Fitting)........... 447 Track Removal And Installation.................................................................. 449 Idler (Front) Removal And Installation.......................................................... 451 Track Tensioner Removal And Installation........................................................ 452 Track Tensioner Disassembly And Assembly........................................................ 453 Idler (Rear) Removal And Installation........................................................... 455 Roller Removal And Installation................................................................. 455 Sprocket Removal And Installation (Single Speed)................................................ 456 Sprocket Removal And Installation (Two-Speed)................................................... 456 Sprocket Removal And Installation (Later Models With Eight Track Sprocket Bolts)................ 456 TRACK UNDERCARRIAGE COMPONENTS (ROLLER SUSPENSION).................................................. 457 Description..................................................................................... 457 Checking (Roller Suspension Undercarriage)...................................................... 459 Adjusting (Roller Suspension Undercarriage) (Earlier Models With Two Track Tension Fittings).... 460 Adjusting (Roller Suspension Undercarriage) (Later Models With One Track Tension Fitting)....... 461 Track Removal And Installation.................................................................. 463 Idler (Front) Removal And Installation.......................................................... 466 Track Tensioner Removal And Installation........................................................ 467 Track Tensioner Disassembly And Assembly........................................................ 468 Idler (Rear) Removal And Installation........................................................... 470 Roller Removal And Installation................................................................. 470 Leaf Spring Removal And Installation............................................................ 471 Sprocket Removal And Installation (Single Speed)................................................ 472 Sprocket Removal And Installation (Two-Speed)................................................... 472 Sprocket Removal And Installation (Later Models With Eight Track Sprocket Bolts)................ 472 TRACK MAINTENANCE................................................................................... 473 Track Damage Identification..................................................................... 473 MAINFRAME............................................................................................... 485 SEAT BAR............................................................................................ 489 Description..................................................................................... 489 Removal And Installation........................................................................ 489 Disassembly And Assembly........................................................................ 490 Compression Spring Disassembly And Assembly..................................................... 491 OPERATOR CAB........................................................................................ 493 Gas Spring Removal And Installation............................................................. 493 Gas Spring Bracket Disassembly And Assembly..................................................... 494 Removal And Installation........................................................................ 494 OPERATOR SEAT....................................................................................... 497 Removal And Installation........................................................................ 497 Seat Belt Removal And Installation (Retractable)................................................ 497 Seat Belt And Bracket Removal And Installation (Standard)....................................... 498 Seat Belt Bracket Removal And Installation...................................................... 498 OPERATOR SEAT (SUSPENSION).......................................................................... 499 Removal And Installation........................................................................ 499 Slide Rail Removal And Installation............................................................. 499 Seat Belt Removal And Installation.............................................................. 500 Lower Cushion Removal........................................................................... 500 Lower Cushion Installation...................................................................... 501 Back Cushion Removal And Installation........................................................... 501 Shock Removal And Installation.................................................................. 502 3-Point Seat Belt Removal And Installation...................................................... 502 BOB-TACH (HAND LEVER)............................................................................... 505 Description..................................................................................... 505 Removal And Installation........................................................................ 505 Lever And Wedge Disassembly And Assembly........................................................ 507 Pivot Pin Bushing And Seal Removal And Installation............................................. 509 BOB-TACH (POWER).................................................................................... 511 Description..................................................................................... 511 Removal And Installation........................................................................ 511 Lever And Wedge Disassembly And Assembly........................................................ 514 Pivot Pin Bushing And Seal Removal And Installation............................................. 516 LIFT ARMS........................................................................................... 517 Stabilizer Bar Removal And Installation......................................................... 517 Link Removal And Installation................................................................... 518 Removal And Installation........................................................................ 519 REAR GRILLE......................................................................................... 523 Removing........................................................................................ 523 Installing...................................................................................... 523 Shield Removal And Installation................................................................. 524 ENGINE COVER........................................................................................ 525 Removal And Installation........................................................................ 525 REAR DOOR (TAILGATE)................................................................................ 527 Removal And Installation........................................................................ 527 Striker Removal And Installation................................................................ 528 Striker Disassembly And Assembly................................................................ 528 Striker (Adjusting)............................................................................. 528 Latch Removal And Installation.................................................................. 529 Tailgate Fan Removal And Installation........................................................... 530 FUEL TANK........................................................................................... 531 Removal And Installation........................................................................ 531 Fuel Level Sender Removal And Installation...................................................... 532 Fuel Fill Screen Removal And Installation....................................................... 533 CONTROL PEDALS AND LINKAGES......................................................................... 535 Description..................................................................................... 535 Pedal Removal And Installation.................................................................. 535 Linkage Removal And Installation................................................................ 536 Pedal (Adjusting)............................................................................... 537 Floor Pan Removal And Installation.............................................................. 538 CONTROL PEDALS AND LINKAGES (ACS)................................................................... 539 Description..................................................................................... 539 Pedal Removal And Installation.................................................................. 539 Linkage Removal And Installation................................................................ 540 Pedal (Adjusting)............................................................................... 540 Floor Pan Removal And Installation.............................................................. 541 CONTROL PANEL....................................................................................... 543 Description..................................................................................... 543 Removal And Installation........................................................................ 544 Disassembly And Assembly........................................................................ 545 Linkage Removal And Installation................................................................ 549 Pintle Arm Disassembly And Assembly............................................................. 553 Linkage NEUTRAL (Adjusting)..................................................................... 554 Linkage Travel (Adjusting)...................................................................... 558 Shock Removal And Installation.................................................................. 562 CONTROL PANEL (SJC)................................................................................. 563 Description..................................................................................... 563 Removal And Installation........................................................................ 563 CONTROL HANDLE / LEVER.............................................................................. 565 Description..................................................................................... 565 Lever Removal And Installation.................................................................. 565 Boot Removal And Installation................................................................... 566 CONTROL HANDLE / LEVER (ACS)........................................................................ 567 Description..................................................................................... 567 Handle Sensor Removal And Installation.......................................................... 567 Handle Removal And Installation................................................................. 570 Handle Disassembly And Assembly................................................................. 571 Lever Removal And Installation.................................................................. 571 Boot Removal And Installation................................................................... 572 CONTROL HANDLE / LEVER (SJC)........................................................................ 573 Description..................................................................................... 573 Joystick Testing................................................................................ 573 Joystick Removal And Installation............................................................... 574 ACCESS PANEL (INSIDE)............................................................................... 575 Removal And Installation (Left)................................................................. 575 Removal And Installation (Right)................................................................ 575 ACCESS PANEL (INSIDE) (SJC)......................................................................... 577 Removal And Installation (Left)................................................................. 577 Removal And Installation (Right)................................................................ 577 WINDOW (REAR)....................................................................................... 579 Rear Window Identification...................................................................... 579 Removal And Installation (Latches).............................................................. 579 Disassembly And Assembly (Latches).............................................................. 580 Removal (Rubber Cord)........................................................................... 580 Installation (Rubber Cord)...................................................................... 581 WINDOW (TOP)........................................................................................ 583 Removal And Installation........................................................................ 583 WINDOW (SIDE)....................................................................................... 585 Removal And Installation........................................................................ 585 CAB DOOR............................................................................................ 587 Description..................................................................................... 587 Removal And Installation........................................................................ 587 Disassembly And Assembly........................................................................ 588 Aligning........................................................................................ 589 Adjusting....................................................................................... 590 Checking Operation.............................................................................. 590 ARMREST............................................................................................. 591 Description..................................................................................... 591 Removal And Installation........................................................................ 592 Disassembly And Assembly........................................................................ 593 LEFT SIDE LOWER PANEL............................................................................... 595 Removal And Installation........................................................................ 595 Disassembly And Assembly........................................................................ 597 RIGHT SIDE LOWER PANEL.............................................................................. 599 Removal And Installation........................................................................ 599 Disassembly And Assembly........................................................................ 600 HEADLINER........................................................................................... 603 Removal And Installation........................................................................ 603 FAN DUCT PANELS..................................................................................... 605 Removal And Installation........................................................................ 605 ELECTRICAL SYSTEM....................................................................................... 607 ELECTRICAL SCHEMATICS............................................................................... 613 ELECTRICAL SYSTEM INFORMATION....................................................................... 767 Glossary Of Electrical Symbols.................................................................. 767 Standard Cab Harness Connectors................................................................. 770 Deluxe Cab Harness Connectors................................................................... 771 Mainframe Manual Harness Connectors............................................................. 772 Mainframe SJC, AHC, ACS Harness Connectors...................................................... 773 Engine Harness Connectors....................................................................... 774 Description..................................................................................... 775 Troubleshooting................................................................................. 776 Fuse And Relay Location / Identification........................................................ 777 Solenoid Testing................................................................................ 783 BATTERY............................................................................................. 785 Removal And Installation........................................................................ 785 Battery Maintenance............................................................................. 786 Maintaining Battery Charge Level................................................................ 786 Battery Service During Machine Storage.......................................................... 786 Battery Testing................................................................................. 787 Battery Charging................................................................................ 787 Using A Booster Battery (Jump Starting)......................................................... 788 ALTERNATOR.......................................................................................... 789 Belt Adjustment................................................................................. 789 Belt Replacement................................................................................ 789 Charging System Inspection...................................................................... 790 Alternator Voltage Testing...................................................................... 791 Low Voltage Testing............................................................................. 791 High Voltage Testing............................................................................ 792 Removal And Installation........................................................................ 793 Parts Identification............................................................................ 795 STARTER............................................................................................. 797 Testing......................................................................................... 797 Removal And Installation........................................................................ 797 Parts Identification............................................................................ 798 INSTRUMENT PANELS................................................................................... 799 Left Panel...................................................................................... 799 Display Screen.................................................................................. 801 Right Panel (Standard Key Panel)................................................................ 802 Right Panel (Keyless Start Panel)............................................................... 803 Right Panel (Deluxe Instrumentation Panel)...................................................... 804 Left Switch Panel............................................................................... 806 Right Switch Panel.............................................................................. 806 Left Side Lower Panel........................................................................... 807 Right Side Lower Panel.......................................................................... 807 Left Panel Removal And Installation............................................................. 808 Right Panel (Standard Key Panel) Removal And Installation....................................... 808 Right Panel (Keyless Start Panel) Removal And Installation...................................... 809 Right Panel (Deluxe Instrumentation Panel) Removal And Installation............................. 809 Key Switch Disassembly And Assembly............................................................. 810 Alarm Disassembly And Assembly.................................................................. 810 Left Switch Panel Removal And Installation...................................................... 811 Right Switch Panel Removal And Installation..................................................... 811 LIGHTS.............................................................................................. 813 Front Removal And Installation.................................................................. 813 Rear Removal And Installation................................................................... 814 Cab Light Removal And Installation.............................................................. 814 BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY).......................................................... 815 Description..................................................................................... 815 Connector Identification........................................................................ 816 Removal And Installation........................................................................ 822 BOBCAT CONTROLLER (ACS)............................................................................. 823 Description..................................................................................... 823 Connector And Wire Identification............................................................... 824 Removal And Installation........................................................................ 825 BOBCAT CONTROLLER (SJC) (DRIVE)..................................................................... 827 Description..................................................................................... 827 Connector Identification........................................................................ 828 Removal And Installation........................................................................ 830 DOSING CONTROL UNIT (DCU)........................................................................... 831 Description..................................................................................... 831 Removal And Installation........................................................................ 831 ENGINE CONTROL UNIT (ECU)........................................................................... 833 Description..................................................................................... 833 Cleaning........................................................................................ 834 Removal And Installation........................................................................ 835 DIAGNOSTIC SERVICE CODES............................................................................ 837 Viewing Service Codes........................................................................... 837 Service Codes List.............................................................................. 838 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)............................................................. 853 Description..................................................................................... 853 Operation....................................................................................... 853 Inspecting The BICS™ (Engine STOPPED - Key ON).................................................. 854 Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)............ 854 Inspecting The Seat Bar Sensor (Engine RUNNING)................................................. 854 Inspecting The Traction Lock And Parking Brake (Engine RUNNING)................................. 854 Inspecting The Lift Arm Bypass Control.......................................................... 854 Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)................................ 854 Troubleshooting................................................................................. 855 SEAT BAR SENSOR..................................................................................... 857 Description..................................................................................... 857 Troubleshooting................................................................................. 857 Testing......................................................................................... 858 Removal......................................................................................... 859 Installation.................................................................................... 860 Bobcat Interlock Control System (BICS™) Circuit Test............................................ 862 TRACTION LOCK....................................................................................... 865 Description..................................................................................... 865 Troubleshooting................................................................................. 866 Inspecting...................................................................................... 867 CONTROL SYSTEM (ACS)................................................................................ 869 Description..................................................................................... 869 Troubleshooting................................................................................. 870 Handle Sensor Connector Disassembly And Assembly................................................ 871 Switch Handle Removal........................................................................... 872 Switch Handle Installation...................................................................... 874 Actuator Connector Disassembly And Assembly..................................................... 877 Handle Lock Solenoid Removal And Installation................................................... 878 Handle Lock Solenoid Disassembly And Assembly................................................... 878 Foot Sensor Removal And Installation............................................................ 879 Foot Sensor Disassembly And Assembly............................................................ 880 Foot Sensor Lock Solenoid Removal And Installation.............................................. 880 ELECTRICAL / HYDRAULIC CONTROLS..................................................................... 881 Identification Chart............................................................................ 881 Description..................................................................................... 882 Identification Chart ACD Group 0................................................................ 883 Identification Chart ACD Group 1................................................................ 884 Identification Chart ACD Group 2................................................................ 885 Identification Chart ACD Group 3................................................................ 886 ELECTRICAL / HYDRAULIC CONTROLS (ACS)............................................................... 887 Identification Chart............................................................................ 887 Description..................................................................................... 888 Identification Chart ACD Group 0................................................................ 889 Identification Chart ACD Group 1................................................................ 890 Identification Chart ACD Group 2................................................................ 891 Identification Chart ACD Group 3................................................................ 892 ELECTRICAL / HYDRAULIC CONTROLS (SJC)............................................................... 893 Identification Chart............................................................................ 893 Description..................................................................................... 894 Identification Chart ACD Group 0................................................................ 895 Identification Chart ACD Group 1................................................................ 896 Identification Chart ACD Group 2................................................................ 897 Identification Chart ACD Group 3................................................................ 898 SERVICE PC (LAPTOP COMPUTER)........................................................................ 899 Connecting Remote Start Tool.................................................................... 899 Connecting Remote Start Tool (Service Tool)..................................................... 899 CALIBRATION......................................................................................... 901 Description..................................................................................... 901 Actuator Testing................................................................................ 901 Lift And Tilt Calibration (SJC)................................................................. 904 Hydrostatic Pump Calibration (SJC).............................................................. 906 Lift And Tilt Calibration (ACS)................................................................. 911 STEERING DRIFT COMPENSATION (OPERATOR MODE)......................................................... 913 Description..................................................................................... 913 Operation....................................................................................... 913 STEERING DRIFT COMPENSATION (SERVICE MODE).......................................................... 915 Description..................................................................................... 915 Operation....................................................................................... 915 CONTROL PANEL SETUP................................................................................. 917 Right Panel Setup (Deluxe Instrumentation Panel)................................................ 917 PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL)....................................................... 921 Password Description............................................................................ 921 Changing The Owner Password..................................................................... 921 Changing The User Passwords..................................................................... 922 Password Lockout Feature........................................................................ 922 PASSWORD SETUP (KEYLESS START PANEL)................................................................ 923 Password Description............................................................................ 923 Changing The Owner Password..................................................................... 923 Password Lockout Feature........................................................................ 923 MAINTENANCE CLOCK................................................................................... 925 Description..................................................................................... 925 Setup........................................................................................... 926 Reset........................................................................................... 929 BACK-UP ALARM SYSTEM................................................................................ 931 Description..................................................................................... 931 Inspection...................................................................................... 931 Adjusting Switch Position....................................................................... 932 Troubleshooting (Standard And ACS).............................................................. 933 Troubleshooting (Joystick)...................................................................... 934 Alarm Removal And Installation.................................................................. 935 Switch Removal And Installation................................................................. 935 FRONT HORN.......................................................................................... 937 Removal And Installation........................................................................ 937 Troubleshooting................................................................................. 938 Troubleshooting (Joystick)...................................................................... 939 CAMSHAFT AND CRANKSHAFT POSITION SENSOR............................................................. 941 Removal And Installation........................................................................ 941 ENGINE COMPARTMENT TEMPERATURE SENSOR............................................................... 943 Removal And Installation........................................................................ 943 BOBCAT MACHINE IQ WIRELESS COMMUNICATIONS........................................................... 945 Description..................................................................................... 945 Removal And Installation........................................................................ 945 Procedure....................................................................................... 946 ENGINE SERVICE.......................................................................................... 947 ENGINE INFORMATION.................................................................................. 951 Description..................................................................................... 951 Specifications.................................................................................. 952 Sensor Location................................................................................. 954 Torque Values................................................................................... 961 Troubleshooting................................................................................. 963 Engine Removal And Installation................................................................. 965 Engine Mount Replacement........................................................................ 976 Compression - Testing........................................................................... 978 Injector Signal - Testing....................................................................... 980 Injector Signal - Testing (In-Line)............................................................. 982 Oil Pressure Testing (At Oil Sensor On Block)................................................... 984 Oil Pressure Testing (At Turbocharger Oil Inlet)................................................ 986 ENGINE SPEED CONTROL (HAND)......................................................................... 989 Removal And Installation........................................................................ 989 ENGINE SPEED CONTROL (FOOT)......................................................................... 991 Removal And Installation........................................................................ 991 Disassembly And Assembly........................................................................ 992 Foot Throttle Calibration....................................................................... 994 SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM.......................................................... 997 Description..................................................................................... 997 Diesel Exhaust Fluid (DEF) / AdBlue® Level...................................................... 998 DeSOX Process................................................................................... 999 SCR System Codes................................................................................1001 Diesel Exhaust Fluid (DEF) / AdBlue® Unsatisfactory Quality.....................................1002 SCR System Component Tampering..................................................................1002 EGR Impeded.....................................................................................1003 Diesel Exhaust Fluid (DEF) / AdBlue® Dosing Interruption........................................1003 SCR Removal And Installation....................................................................1004 Dosing Module Removal And Installation..........................................................1006 Dosing Control Unit (DCU) Removal And Installation..............................................1007 Supply Module Removal And Installation..........................................................1009 Supply Module Filter Removal And Installation...................................................1010 Diesel Exhaust Fluid (DEF) / AdBlue® Tank Removal And Installation..............................1012 Diesel Exhaust Fluid (DEF) / AdBlue® Sensor Removal And Installation............................1015 Diesel Exhaust Fluid (DEF) / AdBlue® Coolant Valve Removal And Installation.....................1017 DIESEL OXIDATION CATALYST (DOC).....................................................................1019 Removal And Installation........................................................................1019 AIR CLEANER.........................................................................................1021 Housing Removal And Installation................................................................1021 ENGINE COOLING SYSTEM...............................................................................1023 Radiator Removal And Installation...............................................................1023 Hydraulic Fan Description.......................................................................1026 Reversible Hydraulic Fan Description............................................................1026 Fan Duct Removal And Installation...............................................................1026 Hydraulic Fan Motor Assembly Removal And Installation...........................................1027 Hydraulic Fan Motor Removal And Installation....................................................1028 Hydraulic Fan Motor Disassembly And Assembly....................................................1030 Blower Housing Removal And Installation.........................................................1038 Water Pump Removal And Installation.............................................................1039 Thermostat Housing Removal And Installation.....................................................1040 Thermostat - Testing............................................................................1040 LUBRICATION SYSTEM..................................................................................1041 Description.....................................................................................1041 Oil Pan Removal And Installation................................................................1042 Oil Pump Removal And Installation...............................................................1043 Oil Pump Relief Valve Description...............................................................1044 Oil Suction Pipe Removal And Installation.......................................................1044 Oil Cooler Removal And Installation.............................................................1045 Oil Filter Head Removal And Installation........................................................1045 Oil Cooler Bypass Description...................................................................1046 FUEL SYSTEM.........................................................................................1047 Description.....................................................................................1047 High Pressure Pump Removal And Installation.....................................................1048 High Pressure Pump Drive Gear Removal And Installation..........................................1049 Fuel Cooler Removal And Installation............................................................1050 Fuel Cooler Bypass Valve Removal And Installation...............................................1050 Fuel Temperature Sensor Removal And Installation................................................1050 Fuel Recirculation Valve Removal And Installation...............................................1051 Fuel Rail Assembly Removal And Installation.....................................................1052 Fuel Injector Removal And Installation..........................................................1053 Injector Coding.................................................................................1055 Removing Air From The Fuel System...............................................................1057 CYLINDER HEAD.......................................................................................1059 Intake Air Heater Removal And Installation......................................................1059 Intake Air Heater Tube Removal And Installation.................................................1060 Valve Clearance Adjustment......................................................................1061 Cylinder Head Removal And Installation..........................................................1063 Cylinder Head Disassembly And Assembly..........................................................1066 Cylinder Head Inspection........................................................................1067 Cylinder Head Top Clearance.....................................................................1068 Valve Step Height...............................................................................1069 Valve Stem Height...............................................................................1069 Valve Guide.....................................................................................1070 Valve...........................................................................................1070 Valve Spring....................................................................................1071 Rocker Arm Shaft Disassembly And Assembly.......................................................1072 Rocker Arm Shaft Inspection.....................................................................1073 Push Rod Inspection.............................................................................1073 CRANKSHAFT AND PISTONS..............................................................................1075 Piston And Connecting Rod Removal And Installation..............................................1075 Piston And Connecting Rod Inspection............................................................1076 Timing Wheel Removal And Installation...........................................................1078 Crankshaft Removal And Installation.............................................................1080 Cylinder Block Inspection.......................................................................1082 Crankshaft Inspection...........................................................................1084 Connecting Rod Inspection.......................................................................1084 Engine Component Class..........................................................................1085 CAMSHAFT............................................................................................1087 Removal And Installation........................................................................1087 Inspecting......................................................................................1088 GEARCASE............................................................................................1091 Gear Backlash...................................................................................1091 Gear End Play...................................................................................1091 Gear Timing.....................................................................................1092 Idle Gear Removal And Installation..............................................................1093 Idle Gear Inspection............................................................................1093 TURBOCHARGER........................................................................................1095 Description.....................................................................................1095 Removal And Installation........................................................................1095 Testing.........................................................................................1097 FLYWHEEL AND HOUSING................................................................................1099 Flywheel Removal And Installation...............................................................1099 Ring Gear Removal And Installation..............................................................1099 Housing Removal And Installation................................................................1100 EXHAUST GAS RECIRCULATION (EGR) SYSTEM..............................................................1101 Description.....................................................................................1101 Removal And Installation........................................................................1102 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................1105 AIR CONDITIONING SYSTEM FLOW........................................................................1107 Description.....................................................................................1107 Chart...........................................................................................1108 Components......................................................................................1109 Safety Equipment................................................................................1112 REGULAR MAINTENANCE.................................................................................1113 Filters.........................................................................................1113 Belt Adjustment.................................................................................1114 Belt Replacement................................................................................1114 Condenser.......................................................................................1115 Air Conditioning Lubrication....................................................................1115 Air Conditioning Service Chart..................................................................1116 Air Conditioning Evaporator / Heater Coil.......................................................1117 TROUBLESHOOTING.....................................................................................1119 Blower Motor Does Not Operate...................................................................1119 Blower Motor Operates Normally, But Air Flow Is Insufficient....................................1119 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal......................1119 The Compressor Does Not Operate At All, Or Operates Improperly..................................1119 Gauge Pressure Related Troubleshooting..........................................................1120 Troubleshooting Tree............................................................................1122 Temperature / Pressure Chart....................................................................1125 Poor A/C Performance............................................................................1127 HVAC Repair And Leaks...........................................................................1128 Electrical System...............................................................................1129 Engine Coolant Bypassing The Heater Valve.......................................................1135 Heater Valve Not Opening Or Closing.............................................................1136 SYSTEM CHARGING AND RECLAMATION.....................................................................1137 Refrigerant Identification......................................................................1137 Reclamation And Charging With Recovery / Charging Unit..........................................1138 COMPRESSOR..........................................................................................1141 Removal And Installation........................................................................1141 Oil.............................................................................................1143 Oil Check.......................................................................................1144 CONDENSER...........................................................................................1145 Removal And Installation........................................................................1145 RECEIVER / DRIER....................................................................................1147 Receiver / Drier Removal And Installation.......................................................1147 Pressure Switch Removal And Installation........................................................1149 Schrader® Valve Removal And Installation........................................................1150 EVAPORATOR / HEATER UNIT............................................................................1151 Removal And Installation........................................................................1151 THERMOSTAT..........................................................................................1153 Description.....................................................................................1153 Removal And Installation........................................................................1154 EXPANSION VALVE.....................................................................................1155 Removal And Installation........................................................................1155 EVAPORATOR COIL.....................................................................................1157 Removal And Installation........................................................................1157 HEATER COIL.........................................................................................1159 Removal And Installation........................................................................1159 BLOWER FAN..........................................................................................1161 Removal And Installation........................................................................1161 Disassembly And Assembly........................................................................1161 HEATER VALVE........................................................................................1165 Removal And Installation........................................................................1165 EVAPORATOR / HEATER COVER...........................................................................1167 Removing........................................................................................1167 Installing......................................................................................1167 SPECIFICATIONS..........................................................................................1169 LOADER SPECIFICATIONS...............................................................................1171 Machine Dimensions..............................................................................1171 Performance.....................................................................................1172 Engine..........................................................................................1172 Drive System....................................................................................1173 Controls........................................................................................1173 Hydraulic System................................................................................1174 Electrical System...............................................................................1175 Capacities......................................................................................1175 Tracks..........................................................................................1176 Ground Pressure.................................................................................1176 TECHINCAL SERVICE GUIDE SPECIFICATIONS..............................................................1177 Engine..........................................................................................1177 Engine Torques..................................................................................1177 Cooling System..................................................................................1177 Loader Torques..................................................................................1178 Hydraulic / Hydrostatic System..................................................................1178 Fuel Consumption................................................................................1178 TORQUE SPECIFICATIONS FOR BOLTS.....................................................................1179 Torque For General SAE Bolts....................................................................1179 Torque For General Metric Bolts.................................................................1180 HYDRAULIC CONNECTION SPECIFICATIONS.................................................................1181 Straight Thread O-ring Fitting..................................................................1181 Flare Fitting...................................................................................1182 Tubelines And Hoses.............................................................................1182 HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS........................................................1183 Specifications..................................................................................1183 CONVERSIONS.........................................................................................1185 Decimal And Millimeter Equivalent Chart.........................................................1185 U.S. To Metric Conversion Chart.................................................................1185 SERVICE TOOLS REQUIRED..............................................................................1187 Remote Start Tools..............................................................................1187 Hydraulic Tools.................................................................................1188 Mainframe And Drive Tools.......................................................................1191 Electrical Tools................................................................................1194 Engine Tools....................................................................................1195 HVAC Tools......................................................................................1200 ALPHABETICAL INDEX......................................................................................1201
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