Bobcat A300Turbo Sna521111001 Service Manual-21416B320051.pdf -Bookmark created by https://wimanual.com MAINTENANCE SAFETY ALPHABETICAL INDEX CONTENTS FOREWORD SAFETY INSTRUCTIONS Fire Prevention SERIAL NUMBER LOCATION Loader Serial Number Engine Serial Number DELIVERY REPORT BOBCAT LOADER INDENTIFICATION SAFETY AND MAINTENANCE LIFTING AND BLOCKING THE LOADER Procedure LIFT ARM SUPPORT DEVICE Installing The Lift Arm Support Device Removing The Lift Arm Support Device OPERATOR CAB Description Raising The Operator Cab Lowering The Operator Cab Emergency Exit TRANSPORTING THE BOBCAT LOADER Procedure TOWING THE LOADER Procedure REMOTE START Procedure For Loader W Procedure For Loader With Attachments Control Harness Procedure SERVICE SCHEDULE Chart AIR CLEANER SERVICE Replacing Filter Element ENGINE COOLING SYSTEM Cleaning Cooling System FUEL SYSTEM Fuel Specifications Filling The Fuel Tank Fuel Filter Removing Air From The Fuel System Fuel Lift Pump Strainer ENGINE LUBRICATION SYSTEM Checking Engine Oil Oil Chart Replacing Oil And Filter HYDRAULIC Checking And Adding Fluid Hydraulic Replacing Hydraulic Fluid Steering Filter Replacement FINAL DRIVE TRANSMISSION (CHAINCASE) Checking And Adding Oil Replacing The Oil FAN GEARBOX Checking And Adding Oil BOB-TACH Inspection And Maintenance POWER BOB-TACH Inspection And Maintenance LUBRICATING THE LOADER Procedure TIRE MAINTENANCE Wheel Nuts Tire Rotation Tire Mounting HYDRAULIC SYSTEM HYDRAULIC HYDRAULIC SYSTEM INFORMATION Troubleshooting Tighten Procedures CYLINDER (LIFT) Checking Removal And Installation Parts Identification Disassembly Assembly CYLINDER (TILT) Checking Removal And Installation Base Pin Removal And Installation Parts Identification Disassembly Assembly CYLINDER (POWER BOB-TACH) Checking Removal And Installation Parts Identification Disassembly Assembly CYLINDER (STEERING) Removal (Front) Removal (Rear) MAIN RELIEF VALVE Checking The Main Relief Valve At Front Auxiliary Hydraulics Removal and Installation Adjustment HYDRAULIC CONTROL VALVE Actuator Removal And Installation (In Loader) Removal And Installation Actuator Removal And Installation (Out Of Loader) BICS� Valve Removal And Installation BICS� Valve Lift Arm By-Pass Orifice Removal And Installation BICS� Valve Check Valve Removal And Installation BICS� Valve Lock Valve Removal And Installation BICS� Valve Soleniod Removal And Installation BICS� Valve Solenoid Testing Identification Chart Lift Base End Restrictor Load Check Valve Main Relief Valve Port Relief Valve Anti-Cavitation Valve Anti-Cavitation Valve Lift Spool Removal And Installation Tilt Spool Removal And Installation Lift And Tilt Spool Disassembly And Assembly Auxiliary Spool Removal And Installation Auxiliary Electric Solenoid Disassembly And Assembly Port-Auxiliary Section Disassembly Cleaning And Inspection LIFT ARM BY-PASS CONTROL VALVE Inspecting Additional Inspection For Loaders W Removal And Installation Disassembly And Assembly HYDRAULIC PUMP Checking The Output Of The Auxiliary Pump Checking The Output Of The Steering Pump Removal And Installation Parts Identification Disassembly And Assembly HYDRAULIC Housing Removal And Installation Mount Removal And Installation HYDRAULIC FLUID RESERVOIR Fluid Removal Removal And Installation Hydraulic Fluid Screen BUCKET POSITION VALVE Solenoid Removal And Installation Solenoid Testing Removal And Installation Disassembly And Assembly REAR AUXILIARY DIVERTER VALVE (EARLY MODELS) Removal and Installation REAR AUXILIARY DIVERTER VALVE (EARLY MODELS) (CONT�D) REAR AUXILIARY DIVERTER VALVE (EARLY MODELS) (CONT�D) Disassembly and Assembly Inspection Solenoid Testing Assembly REAR AUXILIARY DIVERTER (LATER MODELS) Removal and Installation REAR AUXILIARY DIVERTER (LATER MODELS) (CONT�D) Disassembly And Assembly Solenoid Testing Inspection POWER BOB-TACH BLOCK (EARLY MODELS) Removal And Installation Disassembly And Assembly POWER BOB-TACH BLOCK (LATER MODELS) Removal And Installation Disassembly And Assembly FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Removal and Installation Disassembly And Assembly HYDROSTATIC SYSTEM HYDROSTATIC SYSTEM INFORMATION Troubleshooting Chart Replenishing Valve Function HYDROSTATIC MOTOR Removal And Installation Parts Identification Disassembly Inspection Assembly HYDROSTATIC MOTOR CARRIER Removal And Installation Parts Identification Assembly CHARGE PRESSURE Hydrostatic Charge Pressure Sender HYDROSTATIC PUMP Pump Controller Removal And Installation Hydrostatic Pump Calibration Removal And Installation Parts Identification (Right Half) Parts Identification (Left Half) System Check Relief Valves (High Pressure Relief, Charge Check & By-Pass Valve) Charge Relief Valve Pump Separation Shaft Seal And Shaft Replacement Shaft Seal And Shaft Installation Charge Pump Removal Charge Pump Inspection Charge Pump Installation Disassembly Inspection Assembly Pump Neutral Adjustment Pump Controller Neutral Adjustment DRIVE BELT Shield Removal And Installation Adjustment Replacement Tensioner Pulley Removal And Installation Tensioner Pulley Tension Spring OIL COOLER (SEAL TO CONNECT) (STC) Hydraulic Oil Cooler Removal And Installation DRIVE SYSTEM BRAKE Block Removal And Installation Block Disassembly And Assembly STEERING BLOCK Wiring Diagram Removal And Installation Disassembly And Assembly DRIVE COMPONENTS Axle Seal Removal And Installation Axle, Sprocket And Bearings Removal And Installation Drive Chain Removal And Installation CHAINCASE Front Chaincase Cover Removal And Installation Rear Chaincase Cover Removal And Installation HUB Removal Installation Disassembly Inspection Assembly MAIN FRAME SEAT BAR Removal And Installation Assembling Components Compression Spring Disassembly And Assembly OPERATOR CAB Gas Cylinder Removal And Installation (Early Models) Gas Cylinder Removal And Installation (Later Models) Gas Cylinder Bracket Disassembly And Assembly Removal And Installation OPERATOR SEAT Removal And Installation Seat Belt Removal And Installation OPERATOR SEAT (SUSPENSION) Removal And Installation Slide Rail Removal And Installation Cushion Removal And Installation Back Removal And Installation Shock Removal And Installation BOB-TACH Removal And Installation Bob-Tach Lever And Wedge POWER BOB-TACH Removal And Installation Power Bob-Tach Lever And Wedge Pivot Pin Bushing And Seal Replacement LIFT ARMS Stabilizer Bar Removal And Installation Link Removal And Installation Removal And Installation Installation Of Lift Arms REAR GRILL Removal And Installation REAR DOOR Removal And Installation Adjusting The Rear Door Latch FUEL TANK Removal And Installation Fuel Level Sender CONTROL Joystick Testing (Right & Left) Joystick Removal (Right & Left) Joystick Boot Removal (Right & Left) Lever Assembly Removal (Right & Left) CONTROL PANEL Removal And Installation INSIDE ACCESS PANEL Panel Removal (Right) Panel Removal (Left) ELECTRICAL SYSTEM & ANALYSIS ELECTRICAL SCHEMATICS ELECTRICAL SYSTEM INFORMATION Troubleshooting Description Fuse Location Relay Switch Location Solenoid Test BATTERY Removal And Installation Servicing The Electrical System Using A Booster Battery (Jump Starting) ALTERNATOR Adjusting The Alternator Belt Alternator Identification Charging System Check Alternator Voltage Test Low Voltage Test High Voltage Test Removal And Installation Rectifier Continuity (Diode) Test Alternator Regulator Test Disassembly Stator Continuity Test Stator Ground Test Rotor Continuity Test Rotor Ground Test Assembly STARTER Checking Removal And Installation Parts Identification Disassembly And Assembly Inspection And Repair No Load Test INSTRUMENT PANEL Left Panel Right Panel - (Standard) (With Key Switch) Right Panel - (Deluxe) (With Keyless Start) Right Panel Set Up Display Options (Deluxe) Option and Field Accessory Panels (If Equipped) Standard Panel Removal And Installation (Right Side) Deluxe Panel Removal And Installation (Right Side) Standard & Deluxe Panel Removal And Installation (Left Side) LIGHTS Front Removal And Installation Rear Removal And Installation BOBCAT 2001 CONTROLLER Removal And Installation Identification Chart AWS CONTROLLER Removal Identification Chart SPEED SENSOR Testing Removal DIAGNOSTICS SERVICE CODES Display Number Codes List STEERING SOLENOID Removal BICS� SYSTEM 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) Troubleshooting Chart Troubleshooting Guide. SEAT BAR SENSOR Troubleshooting Chart Test Removal And Installation BICS� Circuit Test TRACTION LOCK Troubleshooting Chart Description Of The Control System Inspecting The Control System WHEEL POSITION SENSORS Operation Wheel Alignment (Failed Sensor) Testing Sensor Removal And Installation Wheel Alignment (Field Adjustment) Wheel Alignment (Calibration) SERVICE PC (LAPTOP COMPUTER) Connecting The Service PC To Remote Start Tool LIFT AND TILT ACTUATOR CALIBRATION Procedure ELECTRICAL Controls Identification Chart ENGINE SERVICE TROUBLESHOOTING Chart ENGINE SPEED CONTROL Removal Disassembly Speed Control Cable MUFFLER Removal And Installation AIR CLEANER Housing Removal And Installation RADIATOR Removal And Installation COOLING FAN Drive Tension Pulley Removal And Installation Gearbox Blower Removal And Installation Gearbox Parts Identification Gearbox Disassembly Gearbox Assembly Gearbox, Checking Backlash ENGINE COMPONENTS AND TESTS Engine Compression, Checking Glow Plug, Checking Fuel Shut-Off Solenoid Checking Fuel Shut-Off Solenoid Removal And Installation Fuel Injection Pump Removal Fuel Injection Pump Timing Fuel Injection Pump Installation Fuel Injector Removal And Installation Fuel Injector, Checking Fuel Injector Disassembly Fuel Injector Assembly Timing Belt Inspection Timing Belt Removal Timing Belt Installation Timing Belt, Replacement In The Loader Valve Clearance Adjustment Valve Timing, Checking Thermostat, Oil Pressure Control Valves & Heater Connections ENGINE Removal And Installation Mount Replacement FLYWHEEL AND HOUSING Flywheel Removal And Installation Ring Gear Removal And Installation Flywheel Housing Removal And Installation RECONDITIONING THE ENGINE Deutz Engine Tools Identification Chart Disassembly Assembly Cylinder, Checking Camshaft Bearing, Checking Camshaft Bearing, Removal And Installation Control Rod Guide Bushing Removal Control Rod Guide Bushing Installation Rear Cover Seal Removal And Installation Crankshaft, Checking Connecting Rod, Checking Piston, Checking Piston Pin, Checking Piston Rings Installation Piston Installation On The Connecting Rod Cylinder Head Disassembly Valves, Checking Valve Seats, Checking Cylinder Head Assembly Rocker Arm And Bracket, Checking Front Cover Disassembly Front Cover Assembly Turbo Charger Removal and Installation Crankshaft Gear Mounting Bolt Torque Procedure HEATING, VENTILATION, AIR CONDITIONING AIR CONDITIONING SYSTEM FLOW Principals Chart COMPONENTS Identification SAFETY Safety Equipment REGULAR MAINTENANCE Filter Elements Removal And Installation Compressor Drive Belt Inspection Cleaning The Condenser BASIC TROUBLESHOOTING Poor A Cleaning The A Receiver Compressor Drive Belt Inspection Checking The Electrical System Engine Coolant By-Passing The Heater Valve Heater Valve Not Opening Or Closing GENERAL AIR CONDITIONING SERVICE GUIDELINES Compressor Oil Compressor Oil Check Component Replacement And Refrigeration Leaks SYSTEM TROUBLESHOOTING CHART Gauge Pressure Related Troubleshooting Troubleshooting Tree TEMPERATURE Chart AIR CONDITIONING SERVICE Chart SYSTEM CHARGING AND RECLAMATION Reclamation Procedure Charging Procedure With A Manifold Gauge Set Charging Procedure COMPRESSOR Removal And Installation Compressor Clutch Disassembly CONDENSER Removal And Installation RECEIVER Removal And Installation PRESSURE RELIEF VALVE Removal and Installation PRESSURE SWITCH Removal And Installation EVAPORATOR Removal And Installation Disassembly And Assembly 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 HEATER Removal And Installation Disassembly And Assembly Wire Connector Removal And Installation HEATER VALVE Removal And Installation Disassembly And Assembly SPECIFICATIONS LOADER SPECIFICATIONS (A300) Machine Dimensions Performance Controls Engine Hydraulic System Electrical Drive System Capacities Tires ENGINE SPECIFICATIONS General Fuel System Valve And Valve Guide And Seat Insert Piston And Rings Connecting Rod Cylinder Head And Block Crankshaft And Main Bearings Camshaft And Bearings Oil Pump LOADER TORQUE Specifications TORQUE SPECIFICATIONS FOR BOLTS Torque For General SAE Bolts Torque For General Metric Bolts Torque For Kabota Metric Engine Bolts HYDRAULIC CONNECTION SPECIFICATIONS O-ring Face Seal Connection Straight Thread O-ring Fitting Tubelines And Hoses Flare Fitting O-ring Flare Fitting Port Seal Fitting HYDRAULIC FLUID SPECIFICATIONS Specifications CONVERSIONS Decimal And Millimeter Equivalents SMR Revision No: A300-1 Revision No: A300-2 Revision No: A300-3 Revision No: A300-4 Revision No: A300-5 Revision No: A300-6 . 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