Bobcat T200 Hydraulic Excavator Service Manual 6901397-21416B320159.pdf -Bookmark created by https://wimanual.com MAINTENANCE SAFETY ALPHABETICAL INDEX CONTENTS FOREWORD SAFETY INSTRUCTIONS Fire Prevention SERIAL NUMBER LOCATIONS Loader Serial Number Engine Serial Number DELIVERY REPORT BOBCAT LOADER IDENTIFICATION SAFETY & MAINTENANCE LIFTING AND BLOCKING THE LOADER Procedure LIFT ARM SUPPORT DEVICE Engaging The Lift Arm Support Device Disengaging The Lift Arm Support Device OPERATOR CAB Raising The Operator Cab Lowering the Operator Cab Emergency Exit TRANSPORTING THE BOBCAT LOADER Procedure Stopping The Bobcat Loader TOWING THE LOADER Procedure (S Procedure (S REMOTE START Procedure For Loader Without Attachments Control Harness Procedure For Loader With Attachments Control Harness Procedure SERVICE SCHEDULE Chart AIR CLEANER SERVICE Replacing Filter Element ENGINE COOLING SYSTEM Cleaning The Cooling System FUEL SYSTEM Fuel Specifications Filling the Fuel Tank Fuel Filter Fuel Lift Pump Strainer Removing Air From The Fuel System ENGINE LUBRICATION SYSTEM Checking Engine Oil Replacing Oil And Filter HYDRAULIC Checking And Adding Fluid Hydraulic Replacing Hydraulic Fluid (518911353 & Below) Replacing Hydraulic Fluid (518911354 & Above) FAN GEARBOX Checking And Adding Oil BOB-TACH Inspection And Maintenance POWER BOB-TACH (OPTION) Inspection And Maintenance LUBRICATING THE LOADER Procedure HYDRAULIC SYSTEM HYDRAULIC HYDRAULIC SYSTEM INFORMATION Glossary Of Hydraulic Troubleshooting Tighten Procedures CYLINDER (LIFT) Checking Removal And Installation Parts Identification Disassembly Assembly CYLINDER (TILT) Checking Removal And Installation Rod End Seal Parts Identification Disassembly Assembly CYLINDER (POWER BOB-TACH) Checking Removal And Installation Parts Identification Disassembly Assembly MAIN RELIEF VALVE Checking The Main Relief Valve At Front Auxiliary Hydraulics Removal And Installation Adjustment HYDRAULIC CONTROL VALVE (FOOT CONTROL) Removal And Installation (S Removal And Installation (S BICS� Valve, Removal And Installation BICS� Valve, Lift Arm By-Pass Orifice Disassembly And Assembly BICS� Valve, Check Valve Disassembly And Assembly (S BICS� Valve, Check Valve Disassembly And Assembly (S BICS� Valve, Check Valve Disassembly And Assembly (S BICS� Valve, Lock Valve Disassembly And Assembly BICS� Valve, Solenoid Disassembly And Assembly BICS� Valve, Solenoid Testing Identification Chart Load Check Valve Main Relief Valve Port Relief Valve, Tilt Spool (Linkage End) Port Relief Valve, Lift Spool (Bonnet End) Anti-Cavitation Valve Anti-Cavitation Valve, Lift Spool (Linkage End) Rubber Boot Lift And Tilt Lock Block Lift Spool and Detent Tilt Spool Removal And Installation Auxiliary Spool Removal And Installation (Bonnet End) Auxiliary Spool Removal And Installation (Linkage End) Auxiliary Plug Removal And Installation Auxiliary Electric Solenoid Disassembly Port Relief-Auxiliary Section Disassembly Cleaning And Inspection HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS) Actuator Removal And Installation (In Loader) (S Removal And Installation (S Actuator Removal And Installation (In Loader) (S Actuator Removal And Installation (Out Of Loader) Removal And Installation (S BICS� Valve, Removal And Installation BICS� Valve, Lift Arm By-Pass Orifice Disassembly And Assembly BICS� Valve, Check Valve Disassembly And Assembly BICS� Valve, Lock Valve Disassembly And Assembly BICS� Valve, Solenoid Disassembly And Assembly BICS� Valve, Solenoid Testing Identification Chart Identification Chart Lift Base End Restrictor Load Check Valve Main Relief Valve Port Relief Valve Anti-Cavitation Valve Anti-Cavitation Valve Lift Spool Removal Lift Spool Removal And Installation Lift and Tilt Spool Disassembly And Assembly Auxiliary Spool Removal And Installation Auxiliary Electric Solenoid Disassembly Port-Auxiliary Section Disassembly Cleaning And Inspection LIFT ARM BY-PASS CONTROL VALVE Inspecting Additional Inspection For Loaders With Hand Controls Removal And Installation Disassembly And Assembly HYDRAULIC PUMP (ALUMINUM) Checking The Output Of The Pump (518916260 & Below) Removal And Installation (518916260 & Below) Parts Identification (518916260 & Below) Disassembly (518916260 & Below) Inspection (518916260 & Below) Assembly (518916260 & Below) HYDRAULIC PUMP (ALUMINUM HI-FLOW) Checking The Output Of The High Flow Pump (518916427 & Below) HYDRAULIC PUMP (ALUMINUM HI-FLOW) Checking The Output Of The High Flow Pump (518916427 & Below) Removal And Installation (518916427 & Below) Parts Identification (518916427 & Below) Disassembly (518916427 & Below) Inspection (518916427 & Below) Assembly (518916427 & Below) HYDRAULIC PUMP (CAST IRON) Check Output of the Cast Iron Hydraulic Pump (518916261 & Above) Removal And Installation (518916261 & Above) HYDRAULIC PUMP (CAST IRON) Disassembly And Assembly (518916261 & Above) Hydraulic Pump Test (518916428 & Above) Inline Hydraulic Pump Test (518916428 & Above) (Standard) Inline Hydraulic Pump Test (518916428 & Above) (HI- FLOW) High Flow Relief Adjustment Procedure (518916428 & Above) High Flow Relief Valve Removal and Installation (518916428 & Above) Removal And Installation (518916428 & Above) Identification (518916428 & Above) Disassembly And Assembly (518916428 & Above) HYDRAULIC Housing Removal And Installation (S Mount Removal And Installation Housing Removal And Installation (S HYDRAULIC FLUID RESERVOIR Draining The Hydraulic Fluid Reservoir Removal And Installation Hydraulic Fluid Screen BUCKET POSITION VALVE Solenoid Removal And Installation Solenoid Testing Removal And Installation Disassembly And Assembly SELECT VALVE Checking The High Flow Pump Relief Valve (518916427 & Below) Removal And Installation (518916427 & Below) Disassembly And Assembly (518916427 & Below) Solenoid Testing (518916427 & Below) REAR AUXILIARY DIVERTER VALVE Disassembly Inspection Solenoid Testing Assembly POWER BOB-TACH BLOCK Removal And Installation Disassembly And Assembly AUXILIARY PRESSURE RELEASE (ACCUMULATOR) Removal and Installation (518916010 & Below) Disassembly And Assembly (518916010 & Below) FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Removal And Installation (518916011 & Above) Disassembly And Assembly (518916011 & Above) HYDROSTATIC SYSTEM HYDROSTATIC SYSTEM INFORMATION Troubleshooting Chart Replenishing Valve Function HYDROSTATIC MOTOR Removal And Installation Parts Identification Disassembly Inspection Assembly Filling CHARGE PRESSURE SENDER Removal and Installation Checking Charge Pressure HYDROSTATIC PUMP Removal And Installation Replenishing Parts Identification (Right Half) Parts Identification (Left Half) Hydraulic Pump Removal And Installation Disassembly Assembly DRIVE BELT Shield Removal And Installation Adjustment Replacement Tensioner Pulley Removal And Installation Tensioner Pulley Disassembly And Assembly Tensioner Pulley Tension Spring OIL COOLER Removal and Installation Removal And Installation With STC (Seal Tight Connector) DRIVE SYSTEM BRAKE (S Switch Operated Parking Brake Block Removal And Installation Block Disassembly And Assembly Traction Lock By-Pass Knob BRAKE (S Switch Operated Parking Brake Block Removal And Installation Block Disassembly And Assembly DRIVE COMPONENTS Track Checking Track Adjustment Track Removal And Installation Track Idler (Front) End Play Specifications Track Idler (Front) Removal And Installation Track Idler (Front) Parts Identification (S Track Idler (Front) Disassembly (S Track Idler (Front) Assembly (S Track Idler (Rear) End Play Specifications (S Track Idler (Rear) Removal And Installation (S Track Idler (Rear) Parts Identification Track Idler (Rear) Disassembly (S Track Idler (Rear) Assembly (S Track Roller Assembly End Play Specifications (S Track Roller Parts Identification Track Roller Removal And Installation (S Track Roller Disassembly (S Track Roller Assembly Track Idler (Front) Parts Identification (S Track Idler (Front) Disassembly (S Track Idler (Front) Assembly Track Idler (Rear) End Play Specifications (S Track Idler (Rear) Parts Identification Track Idler (Rear) Removal And Installation Track Idler (Rear) Disassembly (S Track Roller Assembly End Play Specifications (S Track Roller Parts Identification Track Roller Removal And Installation Track Roller Disassembly (S Track Housing Removal And Installation Track Damage Identification MAIN FRAME SEAT BAR Removal And Installation Assembling Components Compression Spring Disassembly And Assembly OPERATOR CAB Gas Cylinder Removal And Installation Gas Cylinder 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 Inspection And Maintenance Bob-Tach Lever And Wedge Removal And Installation Pivot Pin Bushing And Seal Replacement POWER BOB-TACH Inspection And Maintenance Power Bob-Tach Lever And Wedge Removal And Installation Pivot Pin Bushing And Seal Replacement LIFT ARMS Removal And Installation REAR GRILL Removal And Installation REAR DOOR Removal And Installation Adjusting The Rear Door Latch (S Striker Removal And Installation (S Adjusting The Striker (S Latch Removal And Installation (S FUEL TANK Removal And Installation Fuel Level Sender Fuel Pick-up Screen CONTROL PEDALS Control Pedal Removal And Installation Control Pedal Adjustment Crossbar Linkage Removal And Installation Crossbar Linkage Inspection CONTROL PANEL Removal and Installation CONTROL PEDALS (ACS) Foot Sensor Removal And Installation Foot Pedal Removal And Installation Foot Pedal Linkage Disassembly And Assembly CONTROL HANDLE Shock Removal And Installation Shaft Removal And Installation Shaft Disassembly And Assembly Lever Removal And Installation Rubber Boot Replacement Linkage Removal And Installation Linkage Adjustment Linkage Neutral Adjustment CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) advanced hand control Components Identification Handle Sensor Removal And Installation Control Handle Removal and Installation Control Handle Disassembly and Assembly Control Lever Removal and Installation Control Lever Boot CONTROL HANDLE (ADVANCED CONTROL SYSTEM) (ACS) SELECTABLE HAND Components Identification Handle Sensor Removal And Installation Control Handle Removal and Installation Control Handle Disassembly and Assembly Control Lever Removal and Installation Control Lever Removal and Installation (Cont�d) Control Lever Boot ELECTRICAL SYSTEM & ANALYSIS ELECTRICAL SCHEMATICS ELECTRICAL SYSTEM INFORMATION Troubleshooting Chart Description Fuse Location Relay Switch Location Solenoid Test BATTERY Removal And Installation Servicing The Battery Using A Booster Battery ALTERNATOR (90 AMP) 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 (NIPPONDENSO) Removal And Installation Parts Identification Disassembly And Assembly External Pinion Inspection And Repair No Load Test STARTER (VALEO) Checking Removal And Installation Parts Identification Disassembly and Assembly Inspection And Repair No Load Test INSTRUMENT PANEL Left Panel (Standard) Right Panel-Standard Instrument Panel (With Key Switch) Right Panel (Deluxe) (With Keyless Start) Right Panel Setup Display Options (Deluxe) Passwords Option And Field Accessory Panels Standard Panel Removal And Installation (Right Side) Deluxe Panel Removal And Installation (Right Side) Standard And Deluxe Panel Removal And Installation (Left Side) Front Accessory Panel Removal And Installation LIGHTS Front Removal And Installation Rear Removal And Installation BOBCAT CONTROLLER Identification Chart (S BOBCAT CONTROLLER (CONT�D) Identification Chart (S Removal And Installation DIAGNOSTICS SERVICE CODES Display 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) Inspecting The Lift Arm By-Pass Control Additional Inspection For Loaders With Advanced Hand Controls 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 Parking Brake Solenoid Removal And Installation (S Parking Brake Solenoid Removal And Installation (S Traction Lock By-Pass Knob ADVANCED CONTROL SYSTEM (ACS) ADVANCED HAND CONTROL Components Identification Troubleshooting Guide Controller, Connector And Wire Identification ACS Controller Removal And Installation Handle Sensor Connector Switch Handle Removal Switch Handle Installation Actuators Disassembly and Assembly ADVANCED CONTROL SYSTEM (ACS) SELECTABLE HAND Components Identification Troubleshooting Guide Controller, Connector And Wire Identification ACS Controller Removal And Installation Handle Sensor Connector Switch Handle Removal Switch Handle Installation Actuators Disassembly and Assembly Handle Lock Solenoid Removal And Installation Handle Lock Solenoid Disassembly And Assembly Handle Lock Solenoid Connector Calibration Of The ACS System Switchable Hand Hand Controls Only Calibration Procedure Foot Sensor Disassembly And Assembly Foot Sensor Connector Foot Lock Solenoid Removal And Installation Foot Lock Solenoid Connector ELECTRICAL Controls Identification Chart ENGINE SERVICE TROUBLESHOOTING Chart ENGINE SPEED CONTROL Removal And Installation Speed Control Cable Speed Control Linkage MUFFLER Removal And Installation AIR CLEANER Housing Removal And Installation RADIATOR Oil Cooler 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 And Heater Connections ENGINE AND ENGINE MOUNTS Removal And Installation Engine Mount Replacement FLYWHEEL AND HOUSING Flywheel Removal And Installation Ring Gear Removal And Installation Flywheel Housing Removal And Installation RPM SENSOR Adjustment 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 Valve Spring, 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 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 THE 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 (T200) Loader Dimensions Performance Controls Engine Hydraulic System Electrical Drive System Capacities Tracks Ground Pressure 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 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 Specifications CONVERSIONS Decimal And Millimeter Equivalents U.S. To Metric Conversion Chart SMR T200-1 T200-2 T200-3 T200-4 . 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