Bobcat T300 Hydraulic Excavator Service Manual 6901936-21416B320167.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 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 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 ENGINE LUBRICATION SYSTEM Checking Engine Oil Oil Chart Replacing Oil And Filter HYDRAULIC Checking And Adding Fluid Hydraulic Replacing Hydraulic Fluid And Case Drain Filters FAN GEARBOX Checking And Adding Oil BOB-TACH Inspection And Maintenance POWER BOB-TACH Inspection And Maintenance LUBRICATING THE LOADER Procedure HYDRAULIC SYSTEM HYDRAULIC HYDRAULIC SYSTEM INFORMATION Troubleshooting Tightening Procedure 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 MAIN RELIEF VALVE (FOOT CONTROL) Checking The Main Relief Valve At Front Aux. Hyd. Removal And Installation Adjustment MAIN RELIEF VALVE (ACS) Checking The Main Relief Valve At Front Aux. Hyd. Removal And Installation Adjustment HYDRAULIC CONTROL VALVE (FOOT CONTROL) Removal And Installation BICS� Valve, Removal And Installation BICS� Valve, Lift Arm By-Pass Orifice Removal And Installation BICS� Valve, Check Valve Removal And Installation BICS� Valve, Check Valve Removal And Installation (Cont�d) BICS� Valve, Lock Valve Removal And Installation BICS� Valve, Lock Valve Removal And Installation (Cont�d) BICS� Valve, Solenoid Removal And Installation BICS� Valve, Solenoid Removal And Installation (Cont�d) BICS� Valve, Solenoid Testing BICS� Valve, Solenoid Testing Identification Chart Load Check Valve Main Relief Valve Main Relief Valve (Cont�d) Port Relief Valve, Tilt Spool Port Relief Valve, Lift Spool Port Relief Valve, Lift Spool (Cont�d) Anti-Cavitation Valve Anti-Cavitation Valve, Lift Spool Anti-Cavitation Valve, Lift Spool (Cont�d) Rubber Boot Lift And Tilt Lock Block Lift And Tilt Lock Block (Cont�d) Lift Spool And Detent Removal Lift Spool And Detent (Cont�d) Lift Spool And Detent (Cont�d) Lift Spool And Detent (Cont�d) Tilt Spool Removal And Installation Auxiliary Spool Removal And Installation Auxiliary Plug Removal And Installation Auxiliary Electric Solenoid Disassembly Port-Auxiliary Section Removal And Installation Cleaning And Inspection HYDRAULIC CONTROL VALVE (ADVANCED CONTROL SYSTEM) (ACS) Actuator Removal And Installation (In Loader) Actuator Removal And Installation (Out Of Loader) Removal And Installation 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 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 W Removal And Installation Disassembly And Assembly HYDRAULIC PUMP Check The Output Of The Hydraulic Pump W Check The Output Of The Hydraulic Pump W Removal And Installation HYDRAULIC PUMP (CONT'D) Check The Output Of The Hydraulic Pump (S Removal And Installation Identification Disassembly And Assembly HYDRAULIC PUMP (CHARGE) Check The Output Of The Hydraulic Pump Check The Output Of The Hydraulic Pump (Cont�d) HYDRAULIC PUMP (HI FLOW) (S Hydraulic Pump Test Inline Hydraulic Pump Test (Standard) High Flow Relief Adjustment Procedure High Flow Relief Valve Removal and Installation Removal And Installation Identification Disassembly And Assembly HYDRAULIC PUMP (HI FLOW) (S Hydraulic Pump Test Inline Hydraulic Pump Test (Standard) Inline Hydraulic Pump Test (High Flow) High Flow Relief Adjustment Procedure High Flow Relief Valve Removal and Installation Removal And Installation 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 Disassembly and Assembly Inspection Solenoid Testing Assembly REAR AUXILIARY DIVERTER (LATER MODELS) Removal and Installation 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 Filling CHARGE PRESSURE SENDER Testing Removal and Installation Setting Charge Pressure HYDROSTATIC PUMP Removal And Installation Replenishing Parts Identification (Right Half) Parts Identification (Left Half) Hydraulic Pump Removal And Installation Pump Separation Disassembly Assembly 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 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 Track Idler (Front) Disassembly Track Idler (Front) Assembly Track Idler (Rear) End Play Specifications Track Idler (Rear) Parts Identification Track Idler (Rear) Removal And Installation Track Idler (Rear) Disassembly Track Idler (Rear) Assembly Track Roller Assembly End Play Specifications Track Roller Parts Identification Track Roller Removal And Installation Track Roller Disassembly Track Roller Assembly 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 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 PEDALS Removal And Installation Pedal Adjustment CONTROL PEDALS (ACS) Foot Sensor Removal And Installation Foot Pedal Removal And Installation Foot Pedal Linkage Disassembly And Assembly CONTROL PANEL Removal And Installation Shock Removal And Installation Shaft Removal And Installation Shaft Disassembly And Assembly Linkage Removal And Installation Linkage Neutral Adjustment CONTROL HANDLE Lever Removal And Installation Steering 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 Boot INSIDE ACCESS PANEL Removal And Installation (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 Removal And Installation Parts Identification Checking 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 Setup Display Options (Deluxe) Deluxe Panel Setup Passwords (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) Front Accessory Panel Removal And Installation LIGHTS Front Removal And Installation Rear Removal And Installation BOBCAT CONTROLLER Identification Chart Removal And Installation DIAGNOSTICS SERVICE CODES Display Number Codes List 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 Controls System (ACS) or Selectable Joystick Control (SJC) Troubleshooting 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 ADVANCED CONTROL SYSTEM (ACS) 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 FLYWHEEL RPM SENSOR Adjustment ENGINE SERVICE TROUBLESHOOTING Chart ENGINE SPEED CONTROL Removal And Installation Speed Control Cable MUFFLER Removal And Installation AIR CLEANER Housing Removal And Installation RADIATOR Removal And Installation Mount Removal COOLING FAN Drive Tension Pulley Removal And Installation Gearbox 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 And Injector Nozzle Removal And Installation 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 Assembly Removal Injection Pump Assembly Installation Injection Pump Removal and Installation Injection Pump Timing Fan Drive Pulley Disassembly And Assembly Water Pump Disassembly And Assembly Gearcase Cover Disassembly And Assembly Idle Gear And Camshaft Disassembly And Assembly Gearcase Plate 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 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 Thermostat Valve Opening Temperature Radiator Water Leakage Radiator Cap Air Leakage Thermostat Assembly Intake Air Heater Checking the Turbo Charger Compressor Side Wheel Shaft Axial Clearance Radial Clearance Air Cleaner, Intake Pipe, Inlet Pipe And Muffler Oil Pipe 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 LOADER SPECIFICATIONS (T300) Machine Dimensions Performance Controls Engine Hydraulic System Electrical Drive System Capacities Tracks 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 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 T300-1 T300-2 T300-3 . 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