Bobcat A300Turbo Sna526411001 Service Manual-21416B320053.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 IDENTIFICATION 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 Checking The Coolant Level Adding The Coolant FUEL SYSTEM Fuel Specifications Filling The Fuel Tank Fuel Filter Removing Air From The Fuel System ENGINE LUBRICATION SYSTEM Checking Engine Oil Oil Chart Replacing Oil And Filter HYDRAULIC Checking And Adding Fluid Hydraulic Fluid Chart Hydraulic Replacing Hydraulic Fluid And Case Drain Filters FINAL DRIVE TRANSMISSION (CHAINCASE) Checking And Adding Oil Removing 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 Main Relief Adjustment Removal And Installation HYDRAULIC CONTROL VALVE (2 PIECE CASTING) Identification Removal And Installation Actuator Removal And Installation (In Loader) 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 Solenoid 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 HYDRAULIC CONTROL VALVE (1 PIECE CASTING) Identification Removal And Installation Actuator Removal And Installation (In Loader) Identification Chart BICS� Valve, Lift Load Check Valve Removal And Installation Load Check Valve Removal And Installation (Tilt & Auxiliary) Anti-Cavitation Valve (Lift, Rod End) Port Relief Port Relief Port Relief Port Relief Valve Plug Removal End Cap Block Removal and Installation Lift Spool Removal and Installation Auxiliary Spool Removal And Installation Auxiliary Solenoid Disassembly and Assembly BICS� Valve Solenoid Disassembly And Assembly BICS� Valve, Lock Valve Removal And Installation BICS� Valve, Lift Arm By-Pass Orifice Disassembly And Assembly Main Relief Valve BICS� Valve, Check Valve Removal And Installation 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 PUMP (HIgh FLOW) Checking The Output Of The High Flow Pump (30 GPM And 40 GPM) Removal And Installation (30 GPM And 40 GPM) Parts Identification (30 GPM And 40 GPM) Disassembly And Assembly (30 GPM And 40 GPM) 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 HIGH FLOW VALVE Checking The High Flow Relief Valve High Flow Relief Valve Adjustment Procedure Removal and Installation Disassembly And Assembly Solenoid Testing REAR AUXILIARY DIVERTER VALVE Removal And Installation Disassembly And Assembly Solenoid Testing Inspection POWER BOB-TACH BLOCK 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 Disassembly Assembly CHARGE PRESSURE SENDER Testing Removal And Installation 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 Identification 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 Seat Belt Removal And Installation Cushion Removal And Installation Back Removal And Installation Shock Removal And Installation 3-Point Seat Belt 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 Striker Removal and Installation Striker Disassembly and Assembly Door Latch and Catch Adjustment Latch Removal And Installation 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 CONTROLLER Identification Chart Removal And Installation 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 Troubleshooting Chart SEAT BAR SENSOR Troubleshooting Chart Test Removal And Installation BICS� Circuit Test TRACTION LOCK Troubleshooting 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 CALIBRATION Lift And Tilt Calibration Procedure Hydrostatic Pump Calibration ELECTRICAL Controls Identification Chart FLYWHEEL RPM SENSOR Adjustment 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 Mount Removal (Early Loaders) Mount Removal (Later Loaders) COOLING FAN Drive Tension Pulley Removal And Installation Gearbox Blower Removal And Installation Gearbox Parts Identification Gearbox Disassembly Gearbox Assembly Gearbox, Checking Backlash ENGINE Removal And Installation Mount Replacement Removal And Installation Tools FLYWHEEL AND HOUSING Flywheel Removal And Installation Ring Gear Removal And Installation Flywheel Housing Removal And Installation RECONDITIONING THE ENGINE Engine Tools Identification Chart Compression Pressure Cylinder Head Clearance Valve Cover, Injector Nozzle And Seal Removal And Installation Checking Nozzle Injection Pressure Nozzle Spraying Condition Valve Seat Tightness Rocker Arm And Push Rod Disassembly And Assembly Valve Clearance Cylinder Head And Tappet Disassembly And Assembly Selecting Cylinder Head Gasket Disassembly And Assembly Valve Disassembly And Assembly Engine Timing (TDC) Injection Pump Housing Removal Injection Pump Governor Housing Removal And Installation Injection Pump Governor Fork Lever Removal And Installation Injection Pump Governor Lever Removal And Installation Injection Pump Stop Lever Removal And Installation Injection Pump Fuel Camshaft And Governor Weight Removal And Installation Injection Pump Removal and Installation Injection Pump Housing Installation Injection Pump Timing Fan Drive Pulley Disassembly And Assembly Water Pump Disassembly And Assembly Oil Cooler And Water Pipe Disassembly And Assembly Gearcase Cover Disassembly And Assembly Idle Gear And Camshaft Disassembly And Assembly Oil Pan And Oil Strainer Disassembly And Assembly Connecting Rod Cap Disassembly And Assembly Piston Disassembly And Assembly Piston Ring And Connecting Rod Disassembly And Assembly Flywheel And Crankshaft Disassembly And Assembly Bearing Case Cover Disassembly And Assembly Flywheel Housing Disassembly And Assembly Crankcase No. 2 Disassembly And Assembly Crankcase No. 1 And No. 2 Disassembly And Assembly Crankshaft Disassembly And Assembly Cylinder Head Surface Flatness Cylinder Head Flaw Valve Recessing Valve Lapping Clearance Between Valve Stem And Valve Guide Replacing Valve Guide Correcting Valve And Valve Seat Free Length And Tilt Of Valve Spring Valve Spring Setting Load Oil Clearance Between Rocker Arm Shaft And Bearing Oil Clearance Between Tappet And Tappet Guide Bore Timing Gear Backlash Idler Gear Side Clearance Camshaft Side Clearance Camshaft Alignment Cam Height Oil Clearance Between Idler Gear Shaft And Idler Gearing Bushing Replacing Idler Gear Bushing Piston Pin Bore I.D. Oil Clearance Between Piston Pin And Small End Bushing Replacing Small End Bushing Clearance Between Piston Ring And Groove Piston Ring Gap Connecting Rod Alignment Crankshaft Side Clearance Crankshaft Alignment Oil Clearance Between Crankpin And Crankpin Bearing Oil Clearance Between Crankshaft Journal And Crankshaft Bearing Replacing Crankshaft Sleeve Cylinder Bore I.D. Correcting Cylinder (Oversize +0.5 mm) Engine Oil Pressure Rotor Lobe Clearance Clearance Between Outer Rotor And Pump Body Clearance Between Rotor And Cover Relief Valve Thermostat Valve Opening Temperature Radiator Water Leakage Radiator Cap Air Leakage Thermostat Assembly Intake Air Heater Air Cleaner, Intake Pipe, Inlet Pipe And Muffler Oil Pipe Turbocharger 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 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 BLOWER FAN Removal And Installation Disassembly And Assembly Wire Connector Removal and Installation HEATER VALVE Removal and Installation Disassembly And Assembly SPECIFICATIONS A300 LOADER SPECIFICATIONS Machine Dimensions Performance Controls Engine Hydraulic System Electrical Drive System Capacities Tires ENGINE SPECIFICATIONS General Fuel System Valve And Valve Timing Valve Spring Piston And Piston Ring Connecting Rod Cylinder Head Crankshaft Cylinder Bore Oil Pump Rocker Arm Tappet Camshaft Thermostat Timing Gear Intake Air Heater Turbocharger Compressor Shaft TORQUE SPECIFICATIONS FOR BOLTS Torque For General SAE Bolts Torque For General Metric Bolts Torque For Kubota Metric Engine Bolts Tightening Torques For General Use Screws, Bolts And Nuts 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 A300-1 A300-2 A300-3 A300-4 . 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