Bobcat A300 All Wheel Steer Service Manual-21416B320048.pdf -Bookmark created by https://wimanual.com MAINTENANCE SAFETY ALPHABETICAL INDEX CONTENTS FOREWORD SAFETY INSTRUCTIONS FIRE PREVENTION Maintenance Operation Electrical Hydraulic System Fueling Starting Spark Arrestor Exhaust System Welding And Grinding Fire Extinguishers SERIAL NUMBER LOCATIONS Loader Serial Number Engine Serial Number DELIVERY REPORT LOADER IDENTIFICATION SAFETY AND MAINTENANCE LIFTING AND BLOCKING THE LOADER Procedure LIFT ARM SUPPORT DEVICE Installing Removing OPERATOR CAB Description Raising Lowering Cab Door Sensor Special Applications Kit Special Applications Kit Inspection And Maintenance Forestry Door And Window Kit Forestry Door And Window Kit Inspection And Maintenance TRANSPORTING LOADER ON A TRAILER Loading And Unloading Fastening TOWING THE LOADER Procedure REMOTE START TOOL KIT-MEL1563 Remote Start Tool - MEL1563 Service Tool Harness Control - MEL1565 Service Tool Harness Communicator - MEL1566 Remote Start Procedure REMOTE START TOOL (SERVICE TOOL) KIT - 6689779 Description Remote Start Tool (Service Tool) - 6689778 Loader Service Tool Harness - 6689747 Computer Service Tool Harness - 6689746 Remote Start Procedure SERVICE SCHEDULE Chart AIR CLEANER SERVICE Replacing Filter Elements ENGINE COOLING SYSTEM Cleaning Checking Level Removing And Replacing Coolant FUEL SYSTEM Fuel Specifications Biodiesel Blend Fuel Filling The Fuel Tank Fuel Filter Removing Air From The Fuel System ENGINE LUBRICATION SYSTEM Checking And Adding Engine Oil Engine Oil Chart Removing And Replacing Oil And Filter HYDRAULIC Checking And Adding Fluid Hydraulic Removing And Replacing Hydraulic Fluid Removing And Replacing Hydraulic Removing And Replacing Case Drain Filters Removing And Replacing Hydraulic Charge Filter Breather Cap FINAL DRIVE TRANSMISSION (CHAINCASE) Checking And Adding Oil Removing Oil From The Chaincase BOB-TACH (HAND LEVER) Inspection And Maintenance BOB-TACH (POWER) Inspection And Maintenance LUBRICATING THE LOADER Lubrication Locations TIRE MAINTENANCE Wheel Nuts Rotating Mounting SPARK ARRESTOR MUFFLER Cleaning Procedure PIVOT PINS Inspection And Maintenance LOADER STORAGE AND RETURN TO SERVICE Storage Return To Service STOPPING THE ENGINE AND LEAVING THE LOADER Procedure Emergency Exit HYDRAULIC SYSTEM HYDRAULIC HYDRAULIC SYSTEM INFORMATION Glossary Of Hydraulic Troubleshooting CYLINDER (LIFT) Testing Removal And Installation Parts Identification Disassembly Assembly CYLINDER (TILT) Testing Removal And Installation Base End Pivot Pin Removal And Installation Parts Identification Disassembly Assembly CYLINDER (BOB-TACH) Testing Removal And Installation Parts Identification Disassembly Assembly CYLINDER (STEERING) Testing Removal And Installation (Front) Removal And Installation (Rear) Parts Identification Disassembly Assembly MAIN RELIEF VALVE Description Testing Adjusting Removal And Installation HYDRAULIC CONTROL VALVE Description Removal And Installation Actuator Removal And Installation (In Loader) Actuator Removal And Installation (Out of Loader) Identification Chart Mount Bracket Removal And Installation Lift Load Check Valve Removal And Installation Load Check Valve Removal And Installation (Tilt & Auxiliary) Anti-Cavitation Valve Removal And Installation (Lift, Rod End) Port Relief Port Relief Port Relief Port Relief Valve Removal And Installation Plug Removal And Installation End Cap Block Removal And Installation Lift Spool And Detent Removal And Installation Tilt Spool Removal And Installation Auxiliary Spool Removal And Installation Auxiliary Solenoid Removal And Installation Solenoid Removal And Installation Lock Valve Removal And Installation Lift Arm Bypass Orifice Removal And Installation Main Relief Valve Removal And Installation Check Valve Removal And Installation LIFT ARM BYPASS CONTROL VALVE Description Testing Removal And Installation Disassembly And Assembly HYDRAULIC PUMP Description Pump Test At Quick Couplers Direct Pump Test (Standard Section) Direct Pump Test (Charge Section) Direct Pump Test (Steering Section) Removal And Installation Hydraulic Pump Startup Parts Identification Disassembly And Assembly HYDRAULIC PUMP (HIGH FLOW) Description Pump Test At Quick Couplers Direct Pump Test (Standard Section) Direct Pump Test (Charge Section) Direct Pump Test (Steering Section) Direct Pump Test (High Flow Section) Removal And Installation Hydraulic Pump Startup Parts Identification Disassembly And Assembly HYDRAULIC Description Housing Removal And Installation HYDRAULIC FLUID RESERVOIR Description Removal And Installation Hydraulic Fluid Screen OIL COOLER Description Removal And Installation BUCKET POSITION VALVE Description Solenoid Removal And Installation Solenoid Testing Removal And Installation Disassembly And Assembly REAR AUXILIARY DIVERTER VALVE Description Solenoid Testing Removal And Installation Disassembly And Assembly BOB-TACH (POWER) BLOCK Description Removal And Installation Disassembly And Assembly FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Description Removal And Installation Disassembly And Assembly HIGH FLOW VALVE Description High Flow Relief Valve Testing High Flow Relief Valve Adjustment Solenoid Testing Removal And Installation Disassembly And Assembly HYDROSTATIC SYSTEM HYDROSTATIC SYSTEM INFORMATION Troubleshooting Description HYDROSTATIC MOTOR (TWO-SPEED) Description Removal And Installation Parts Identification Disassembly Assembly HYDROSTATIC MOTOR CARRIER Description Removal and Installation Parts Identification Disassembly Assembly CHARGE PRESSURE Description Testing Sender Removal And Installation Adjusting HYDROSTATIC PUMP Description Hydraulic Controller Removal And Installation Removal And Installation Hydrostatic Pump Startup Parts Identification High Pressure Relief And Bypass Valve Charge Relief Valve Disassembly And Assembly Mechanical Neutral Adjustment Hydraulic Controller Neutral Adjustment DRIVE BELT Description Shield Removal And Installation Adjusting Belt Removal And Installation Tensioner Pulley Removal And Installation Tensioner Pulley Disassembly And Assembly Tensioner Pulley Tension Spring Removal And Installation Tensioner Pulley Tension Spring Disassembly And Assembly CASE DRAIN FILTER Description Disassembly And Assembly DRIVE SYSTEM BRAKE Description Block Removal And Installation Block Disassembly And Assembly STEERING BLOCK Description Identification Removal And Installation Disassembly And Assembly DRIVE COMPONENTS Description Axle Seal Removal And Installation Axle, Sprocket And Bearings Removal And Installation Chain Removal And Installation CHAINCASE Description Front Cover Removal And Installation Center Cover Removal And Installation Rear Cover Removal And Installation HUB Description Removal Installation Disassembly Assembly MAIN FRAME SEAT BAR Description Removal And Installation Disassembly And Assembly Compression Spring Disassembly And Assembly OPERATOR CAB Gas Cylinder Removal And Installation Gas Cylinder Bracket Disassembly And Assembly Removal And Installation OPERATOR SEAT (SUSPENSION) Removal And Installation Slide Rail Removal And Installation Seat Belt Removal And Installation Lower Cushion Removal And Installation Back Cushion Removal And Installation Shock Removal And Installation 3-Point Seat Belt Removal And Installation BOB-TACH (HAND LEVER) Description Removal And Installation Lever And Wedge Disassembly And Assembly Pivot Pin Bushing And Seal Removal And Installation BOB-TACH (POWER) Description Removal And Installation Lever And Wedge Disassembly And Assembly Pivot Pin Bushing And Seal Removal And Installation LIFT ARMS Stabilizer Bar Removal And Installation Link Removal And Installation Removal And Installation REAR GRILL Removal And Installation REAR DOOR Removal And Installation Striker Removal And Installation Striker Disassembly And Assembly Striker (Adjusting) Latch Removal And Installation FUEL TANK Removal And Installation Fuel Level Sender Removal And Installation Fuel Fill Screen Removal And Installation CONTROL PANEL Description Removal And Installation JOYSTICK CONTROL Description Testing Removal And Installation Mount Removal And Installation ACCESS PANEL (INSIDE) Removal And Installation (Left) Removal And Installation (Right) WINDOW (REAR) Removal Installation WINDOW (TOP) Removal And Installation WINDOW (SIDE) Removal And Installation WINDOW (CAB DOOR) Removal (Standard Window) Installation (Standard Window) Removal And Installation (Special Applications Window) CAB DOOR Description Removal And Installation Aligning Adjusting Checking Operation ELECTRICAL SYSTEM & ANALYSIS ELECTRICAL SCHEMATICS ELECTRICAL SYSTEM INFORMATION Glossary Of Electrical Symbols Cab Harness Connectors Mainframe Harness Connectors Description Troubleshooting Fuse And Relay Location Solenoid Testing BATTERY Removal And Installation Servicing Using A Booster Battery (Jump Starting) ALTERNATOR Belt Adjustment Belt Replacement Charging System Inspection Alternator Voltage Testing Low Voltage Testing High Voltage Testing Removal And Installation Parts Identification STARTER Testing Removal And Installation Parts Identification INSTRUMENT PANELS Left Panel Standard Key Panel Deluxe Instrumentation Panel Side Panel Front Panel Front Panel Removal And Installation Removal And Installation (Left And Right) Key Switch Removal And Installation Alarm Removal And Installation LIGHTS Front Removal And Installation Rear Removal And Installation Cab Light Removal And Installation BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) Description Connector Identification Removal And Installation BOBCAT CONTROLLER (ACS) Description Connector And Wire Identification Removal And Installation BOBCAT CONTROLLER (DRIVE PLUS) Description Connector Identification Removal And Installation SPEED SENSORS Description Testing Removal And Installation WHEEL POSITION SENSORS Description Wheel Alignment (Failed Sensor) Testing Sensor Removal And Installation Wheel Alignment (Field Adjustment) Wheel Alignment (Calibration) DIAGNOSTIC SERVICE CODES Viewing Service Codes (Standard Key Panel) Viewing Service Codes (Deluxe Instrumentation Panel) Service Codes List STEERING SOLENOIDs Description Removal and Installation BOBCAT INTERLOCK CONTROL SYSTEM (BICS) Description Inspecting The BICS Controller (Engine STOPPED - Key ON) Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON) Inspecting The Seat Bar Sensor (Engine RUNNING) Inspecting The Traction Lock (Engine RUNNING) Inspecting The Lift Arm Bypass Control Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) Troubleshooting SEAT BAR SENSOR Description Troubleshooting Testing Removal And Installation Bobcat Interlock Control System (BICS) Circuit Test TRACTION LOCK Description Troubleshooting Inspecting ELECTRICAL Identification Chart SERVICE PC (LAPTOP COMPUTER) Connecting Remote Start Tool Connecting Remote Start Tool (Service Tool) CALIBRATION Description Actuator Testing Lift And Tilt Calibration (SJC) Hydrostatic Pump Calibration (SJC) STEERING DRIFT COMPENSATION Description Operation FLYWHEEL RPM SENSOR Description Adjusting CONTROL PANEL SETUP Right Panel Setup (Deluxe Instrumentation Panel) Attachment Control Information (Deluxe Instrumentation Panel) PASSWORD SETUP Password Description Changing The Owner Password Changing The User Passwords Password Lockout Feature MAINTENANCE CLOCK Description Setup Reset BACK-UP ALARM SYSTEM Description Inspecting Troubleshooting (Joystick) Alarm Removal And Installation ENGINE SERVICE ENGINE INFORMATION Description Specifications Torque Values Troubleshooting Engine Removal And Installation Engine Mount Replacement Compression - Checking ENGINE SPEED CONTROL Removal And Installation Disassembly And Assembly Cable Removal And Installation MUFFLER Removal And Installation AIR CLEANER Housing Removal And Installation ENGINE COOLING SYSTEM Radiator Removal And Installation Radiator Mount Removal And Installation Hydraulic Fan Motor Description Axial Fan Housing Removal And Installation Axial Fan Removal And Installation Hydraulic Fan Motor Removal And Installation Hydraulic Fan Motor Disassembly And Assembly Water Pump Removal And Installation Water Pump Disassembly And Assembly Thermostat Housing Removal And Installation Thermostat Checking LUBRICATION SYSTEM Oil Pan Removal And Installation Oil Pump Removal And Installation Oil Pump Inspection Oil Filter Cooler Removal And Installation Engine Oil Pressure - Testing FUEL SYSTEM Fuel Shutoff Solenoid - Checking Fuel Shutoff Solenoid - Removal And Installation Fuel Injection Pump Assembly Removal Fuel Injection Pump Assembly Installation Governor Housing Disassembly And Assembly Governor Disassembly And Assembly Fuel Camshaft Removal And Installation Fuel Injection Pump Removal Fuel Injection Pump - Timing Fuel Injector Removal And Installation Fuel Injector Nozzle Pressure - Checking Nozzle Spraying Condition Valve Seat Tightness CYLINDER HEAD Intake Air Heater - Testing Intake Air Heater Removal And Installation Valve Clearance Adjustment Valve Timing - Checking Cylinder Head Removal And Installation Cylinder Head Disassembly And Assembly Cylinder Head - Servicing Cylinder Head Top Clearance Valve Guide - Checking Reconditioning The Valve And Valve Seat Valve Spring Valve Tappets Rocker Arm And Shaft - Checking Push Rod Alignment - Checking CRANKSHAFT AND PISTONS Piston And Connecting Rod Removal And Installation Piston And Connecting Rod - Servicing Cylinder Bore Checking Connecting Rod Alignment Crankshaft Gear Removal And Installation Crankshaft And Bearings Removal Crankshaft And Bearings Installation Crankshaft And Bearings - Servicing CAMSHAFT AND TIMING GEArS Timing Gearcase Cover Removal And Installation Timing Gears Backlash - Checking Idler Gear And Camshaft Removal And Installation Camshaft - Servicing Idler Gear And Shaft - Servicing TURBOCHARGER Description Testing Removal And Installation FLYWHEEL AND HOUSING Flywheel Removal And Installation Ring Gear Removal And Installation Housing Removal And Installation EXHAUST GAS RECIRCULATION (EGR) SYSTEM Description Testing Removal And Installation HEATING, VENTILATION, AIR CONDITIONING AIR CONDITIONING SYSTEM FLOW Description Chart Components Safety Equipment REGULAR MAINTENANCE Filters Compressor Drive Belt Adjustment Compressor Drive Belt Replacement Condenser Air Conditioning Lubrication Air Conditioning Service Chart Evaporator TROUBLESHOOTING Blower Motor Does Not Operate Blower Motor Operates Normally, But Air Flow Is Insufficient Insufficient Cooling Although Air Flow And Compressor Operation Are Normal The Compressor Does Not Operate At All, Or Operates Improperly Gauge Pressure Related Troubleshooting Troubleshooting Tree Temperature Poor A HVAC Repair And Leaks Electrical System Engine Coolant Bypassing The Heater Valve Heater Valve Not Opening Or Closing SYSTEM CHARGING AND RECLAMATION Refrigerant Identification Reclamation And Charging With Recovery Charging With A Manifold Gauge Set COMPRESSOR Belt Adjustment Removal And Installation Oil Oil Check Clutch Disassembly And Assembly CONDENSER Removal And Installation RECEIVER Receiver Pressure Relief Valve Removal And Installation Pressure Switch Removal And Installation Schraeder Valve Removal And Installation EVAPORATOR Removal And Installation THERMOSTAT Removal And Installation EXPANSION VALVE Removal And Installation EVAPORATOR Removal And Installation HEATER COIL Removal And Installation With A Removal And Installation Without A BLOWER FAN Removal And Installation Disassembly And Assembly Connector Identification HEATER VALVE Removal And Installation Disassembly And Assembly SPECIFICATIONS (A300) LOADER SPECIFICATIONS Machine Dimensions Performance Engine Controls Drive System Hydraulic System Electrical Capacities Tires TORQUE SPECIFICATIONS FOR BOLTS Torque For General SAE Bolts Torque For General Metric Bolts HYDRAULIC CONNECTION SPECIFICATIONS O-ring Face Seal Connection Straight Thread O-ring Fitting Tubelines And Hoses Flare Fitting Port Seal Fitting HYDRAULIC Specifications CONVERSIONS Decimal And Millimeter Equivalents U.S. To Metric Conversion Chart SMR A300-1 A300-2 . 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