Bobcat T300 TURBO - HIGH FLOW Compact Track Loader Repair Service Manual - 6901936

(S/N: 521911001 & Above - S/N: 522011001 & Above) 
- 
This workshop repair service manual PDF download for the T300 Bobcat Compact Track Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Loader T300 
TURBO - HIGH FLOW
S/N: 521911001 & Above
S/N: 522011001 & Above


TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATION
DELIVERY REPORT
LOADER IDENTIFICATION
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
HEATING, VENTILATION, AIR CONDITIONING
SPECIFICATIONS
SERVICE MANUAL REVISION


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6901936 (3-06)
Total Pages : 776


This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

-

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/O Attachments Control Harness
        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/HYDROSTATIC SYSTEM
        Checking And Adding Fluid
        Hydraulic/Hydrostatic Filter Replacement
        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/HYDROSTATIC SCHEMATICS
    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/Port Relief Valve, Tilt Spool
        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/Port Relief 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/Advanced Hand Controls
        Removal And Installation
        Disassembly And Assembly
    HYDRAULIC PUMP
        Check The Output Of The Hydraulic Pump W/O Power Bob-Tach (S/N 521911523 & Below)
        Check The Output Of The Hydraulic Pump W/Power Bob-Tach. (S/N 521911523 & Below)
        Removal And Installation
    HYDRAULIC PUMP (CONT'D)
        Check The Output Of The Hydraulic Pump (S/N 521911524 & Above)
        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/N 521911523 & BELOW)
        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/N 521911524 & ABOVE)
        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/HYDROSTATIC FILTER
        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/High Pressure Relief Valve
        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/FOOT 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
    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/Foot Controls Calibration Procedure
        Hand Controls Only Calibration Procedure
        Foot Sensor Disassembly And Assembly
        Foot Sensor Connector
        Foot Lock Solenoid Removal And Installation
        Foot Lock Solenoid Connector
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
        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/Blower Housing 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 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/C Performance
        Cleaning The A/C Evaporator Coil & Heater Coil
        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/PRESSURE
        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/DRIER
        Removal And Installation
    PRESSURE RELIEF VALVE
        Removal And Installation
    PRESSURE SWITCH
        Removal And Installation
    EVAPORATOR/HEATER UNIT
        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/C
        Removal And Installation Without A/C
    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
        
SERVICE MANUAL REVISION
    T300-1
    T300-2
    T300-3
    
    -