BOBCAT B300 B-Series SN 572311001 Service Manual PDF DOWNLOAD
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BOBCAT B300 B-Series SN 572311001 Service Manual PDF DOWNLOAD
Language : English
Pages : 752
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TABLE OF CONTENTS:
BOBCAT B300 B-Series SN 572311001 Service Manual PDF DOWNLOAD
MAINTENANCE SAFETY…………………………………….. 3
ALPHABETICAL INDEX…………………………………….. 5
CONTENTS……………………………………………… 7
FOREWORD………………………………………….. 8
SAFETY INSTRUCTIONS………………………………… 11
Fire Prevention………………………………… 13
SERIAL NUMBER LOCATION……………………………… 15
Loader Backhoe Serial Number…………………….. 15
Engine Serial Number……………………………. 15
DELIVERY REPORT……………………………………. 16
LOADER BACKHOE IDENTIFICATION……………………….. 17
SAFETY AND MAINTENANCE…………………………………. 19
LIFTING AND BLOCKING THE LOADER BACKHOE………………. 21
Procedure……………………………………… 21
APPROVED LIFT ARM SUPPORT DEVICE…………………….. 23
Installing The Approved Lift Arm Support Device……. 23
Removing The Approved Lift Arm Support Device……… 24
ENGINE COVER………………………………………. 25
TRANSPORTING THE LOADER BACKHOE……………………… 27
Procedure……………………………………… 27
TOWING THE LOADER BACKHOE…………………………… 29
Procedure……………………………………… 29
AXLE TOE-IN……………………………………….. 31
Procedure……………………………………… 31
SERVICE SCHEDULE…………………………………… 33
Chart…………………………………………. 33
AIR CLEANER SERVICE………………………………… 35
Replacing The Filter……………………………. 35
ENGINE COOLING SYSTEM………………………………. 37
Coolant Replacement…………………………….. 37
FUEL SYSTEM……………………………………….. 39
Fuel Specifications…………………………….. 39
Filling The Fuel Tank…………………………… 39
Fuel Filter……………………………………. 40
Removing Air From The Fuel System………………… 40
ENGINE LUBRICATION SYSTEM…………………………… 41
Checking Engine Oil…………………………….. 41
Oil Chart……………………………………… 41
Replacing Oil And Filter………………………… 42
HYDRAULIC/HYDROSTATIC SYSTEM………………………… 45
Checking And Adding Fluid……………………….. 45
Cleaning The Cooler…………………………….. 45
Replacing Hydraulic/Hydrostatic Filter……………. 46
Replacing Hydraulic Fluid……………………….. 47
REAR AXLE…………………………………………. 49
Checking Oil Level……………………………… 49
Draining Oil…………………………………… 49
FRONT AXLE………………………………………… 51
Checking Oil Level……………………………… 51
Draining Oil…………………………………… 51
BOOM LOCK PIN……………………………………… 53
Engaging And Disengaging The Pin…………………. 53
BOB-TACH HAND LEVER………………………………… 55
Inspection And Maintenance………………………. 55
ALTERNATOR BELT……………………………………. 57
Adjusting The Alternator Belt……………………. 57
LUBRICATING THE LOADER BACKHOE………………………. 59
TIRE MAINTENANCE…………………………………… 67
Wheel Nuts…………………………………….. 67
Mounting………………………………………. 67
Tire Pressure………………………………….. 67
HYDRAULIC SYSTEM………………………………………. 69
HYDRAULIC/HYDROSTATIC SCHEMATIC……………………… 73
HYDRAULIC SYSTEM INFORMATION………………………… 75
Troubleshooting………………………………… 79
Description……………………………………. 80
ARM CYLINDER………………………………………. 81
Checking………………………………………. 81
Removal And Installation………………………… 82
Parts Identification……………………………. 85
Disassembly……………………………………. 86
Assembly………………………………………. 88
BOOM CYLINDER……………………………………… 91
Checking………………………………………. 91
Removal And Installation………………………… 93
Parts Identification……………………………. 96
Disassembly……………………………………. 97
Assembly………………………………………. 99
SWING CYLINDER……………………………………..103
Checking……………………………………….103
Removal And Installation…………………………104
Parts Identification…………………………….106
Disassembly…………………………………….107
Assembly……………………………………….109
BUCKET CYLINDER…………………………………….113
Checking……………………………………….113
Removal And Installation…………………………115
Parts Identification…………………………….118
Disassembly…………………………………….119
Assembly……………………………………….121
STABILIZER CYLINDER…………………………………123
Checking……………………………………….123
Removal And Installation…………………………125
Parts Identification…………………………….127
Disassembly…………………………………….128
Assembly……………………………………….132
TILT CYLINDER………………………………………137
Checking……………………………………….137
Removal And Installation…………………………138
Parts Identification…………………………….140
Disassembly…………………………………….141
Assembly……………………………………….143
LIFT CYLINDER………………………………………145
Checking……………………………………….145
Removal And Installation…………………………146
Parts Identification…………………………….148
Disassembly…………………………………….149
Assembly……………………………………….151
STEERING CYLINDER (FRONT)……………………………155
Removal And Installation…………………………155
Parts Identification…………………………….159
Disassembly And Assembly…………………………160
Inspection……………………………………..163
STEERING CYLINDER (REAR)…………………………….165
Removal And Installation…………………………165
Parts Identification…………………………….168
Disassembly And Assembly…………………………169
Inspection……………………………………..172
MAIN RELIEF VALVE…………………………………..173
Testing The Main Relief Valve…………………….173
Adjustment……………………………………..174
PORT RELIEF VALVE (BACKHOE CONTROL VALVE)……………..175
Testing And Adjusting (Arm Control)……………….175
Testing And Adjusting (Boom Control)………………177
Testing And Adjusting (Boom Swing Control)…………179
LOADER CONTROL VALVE………………………………..181
Removal And Installation…………………………181
Parts Identification…………………………….183
Disassembly And Assembly…………………………184
Inlet/Outlet Valve Section……………………….184
Lift Arm Valve Section…………………………..186
Tilt Valve Section………………………………190
Auxiliary Valve Section (Front)…………………..195
BACKHOE CONTROL VALVE……………………………….201
Removal And Installation…………………………201
Parts Identification…………………………….203
Disassembly And Assembly…………………………204
Inlet/Outlet Valve Section……………………….206
Arm Valve Section……………………………….208
Tilt Valve Section………………………………211
Right Stabilizer Valve Section……………………214
Left Stabilizer Valve Section…………………….217
Boom Valve Section………………………………221
Boom Swing Valve Section…………………………224
Outlet Valve Section…………………………….227
HYDRAULIC FLUID RESERVOIR……………………………229
Removal And Installation…………………………229
Strainer Removal And Installation…………………231
HYDRAULIC FILTER HOUSING…………………………….233
Removal And Installation…………………………233
Disassembly…………………………………….234
Assembly……………………………………….235
HYDRAULIC FILTER……………………………………237
Removal And Installation…………………………237
GEAR PUMP………………………………………….239
Removal And Installation…………………………239
Parts Identification…………………………….240
Disassembly And Assembly…………………………241
Inspection……………………………………..244
STEERING PUMP………………………………………245
Removal And Installation…………………………245
Parts Identification…………………………….247
Disassembly…………………………………….248
Inspection……………………………………..257
Assembly……………………………………….257
STEERING VALVE……………………………………..267
Removal And Installation…………………………267
Adjustment……………………………………..268
MASTER CYLINDER…………………………………….269
Removal And Installation…………………………269
Parts Identification…………………………….270
Disassembly And Assembly…………………………271
HYDROSTATIC SYSTEM……………………………………..273
HYDROSTATIC SYSTEM INFORMATION……………………….275
Troubleshooting Chart……………………………275
Replenishing Valve Function………………………276
OIL COOLER…………………………………………277
Disassembly…………………………………….277
Inspection……………………………………..278
Assembly……………………………………….278
HYDROSTATIC DRIVE MOTOR……………………………..281
Removal And Installation…………………………281
Parts Identification…………………………….283
Disassembly…………………………………….285
Inspection……………………………………..300
Assembly……………………………………….303
HYDROSTATIC PUMP……………………………………319
Removal And Installation…………………………319
Parts Identification…………………………….322
Disassembly…………………………………….324
Inspection……………………………………..337
Assembly……………………………………….339
HYDROSTATIC PUMP TESTING…………………………….355
Hydrostatic Pump Work Sheet………………………355
Pump Testing……………………………………358
DRIVE SYSTEM…………………………………………..363
PARKING BRAKE………………………………………367
Lever Removal And Installation……………………367
Cable Removal And Installation……………………369
Adjustment……………………………………..370
PARKING BRAKE HOUSING……………………………….371
Removal And Installation…………………………371
Parts Identification…………………………….372
Disassembly And Assembly…………………………373
SERVICE BRAKE………………………………………383
Description…………………………………….383
Bleeding The Brake Circuit……………………….383
REAR AXLE………………………………………….385
Removal………………………………………..385
Installation……………………………………388
AXLE AND DIFFERENTIAL (REAR)…………………………393
Troubleshooting Chart……………………………393
General Information……………………………..394
Planetary Carrier Parts Identification…………….394
Planetary Carrier Disassembly…………………….395
Planetary Carrier Inspection……………………..397
Wheel Hub/Brake Group Parts Identification…………398
Wheel Hub/Brake Group Disassembly…………………399
Steering Knuckle Parts Identification……………..405
Steering Knuckle Disassembly……………………..406
Axle Housing/Drive Axle Parts Identification……….408
Axle Housing/Drive Axle Disassembly……………….409
Differential Carrier Removal……………………..412
Differential Carrier Disassembly………………….413
Pinion Group Parts Identification…………………415
Pinion Group Disassembly…………………………416
Inspection……………………………………..418
Pinion Group Inspection………………………….421
Differential Parts Identification…………………422
Differential Disassembly…………………………422
Differential Inspection………………………….425
Differential Assembly……………………………427
Pinion Group Assembly……………………………430
Differential Carrier Assembly…………………….439
Differential Carrier Installation…………………442
Axle Housing/Drive Axle Assembly………………….443
Steering Knuckle Assembly………………………..446
Wheel Hub/Brake Group Assembly……………………449
Planetary Carrier Assembly……………………….454
STEERING ANGLE ADJUSTMENT (REAR AXLE)…………………457
Adjustment……………………………………..457
FRONT AXLE…………………………………………459
Removal………………………………………..459
Installation……………………………………461
Axle Pivot Bushing Removal And Installation………..463
AXLE AND DIFFERENTIAL (FRONT)………………………..465
Troubleshooting Chart……………………………465
General Information……………………………..466
Planetary Carrier Parts Identification…………….466
Planetary Carrier Disassembly…………………….467
Planetary Carrier Inspection……………………..469
Wheel Hub Parts Identification……………………470
Wheel Hub Disassembly……………………………471
Wheel Hub Inspection…………………………….474
Steering Knuckle Parts Identification……………..474
Steering Knuckle Disassembly……………………..475
Axle Housing/Drive Axle Parts Identification……….477
Axle Housing/Drive Axle Disassembly……………….478
Differential Carrier Removal……………………..481
Differential Carrier Disassembly………………….482
Pinion Group Parts Identification…………………484
Pinion Group Disassembly…………………………485
Pinion Group Inspection………………………….487
Differential Parts Identification…………………488
Differential Disassembly…………………………488
Differential Inspection………………………….491
Differential Assembly……………………………492
Pinion Group Assembly……………………………495
Differential Carrier Assembly…………………….501
Axle Housing/Drive Axle Assembly………………….506
Steering Knuckle Assembly………………………..509
Wheel Hub Assembly………………………………512
Planetary Carrier Assembly……………………….514
STEERING ANGLE ADJUSTMENT (FRONT AXLE)………………..517
Adjustment……………………………………..517
DRIVESHAFT…………………………………………519
Removal And Installation…………………………519
DROP BOX…………………………………………..521
Removal And Installation…………………………521
Parts Identification…………………………….524
Disassembly…………………………………….526
Inspection……………………………………..531
Assembly……………………………………….533
MAIN FRAME…………………………………………….541
OPERATOR CANOPY…………………………………….543
Removal And Installation…………………………543
ENCLOSED CAB……………………………………….549
Not Available At Time Of Print……………………549
OPERATOR SEAT………………………………………551
Removal And Installation…………………………551
FLOOR PANELS……………………………………….553
Front Panel Removal And Installation………………553
Rear Panel Removal And Installation……………….553
Front Right Panel Removal And Installation…………554
Front Left Panel Removal And Installation………….554
GRILL……………………………………………..555
Removal And Installation…………………………555
GRILL FRAME………………………………………..557
Removal And Installation…………………………557
ENGINE SIDE COVERS………………………………….559
Removal And Installation…………………………559
FENDER…………………………………………….561
Removal And Installation…………………………561
ENGINE COVER……………………………………….563
Removal And Installation…………………………563
FUEL TANK………………………………………….565
Removal And Installation…………………………565
Screen Removal And Installation…………………..567
LIFT ARMS………………………………………….569
Removal And Installation…………………………569
BOB-TACH…………………………………………..575
Removal And Installation…………………………575
Bob-Tach Lever And Wedge…………………………576
Pivot Pin Bushing Removal And Installation…………578
ARM……………………………………………….579
Removal And Installation…………………………579
Arm Pivot Bushing Removal And Installation…………581
BOOM………………………………………………583
Removal And Installation…………………………583
Boom Pivot Bushing Removal And Installation………..584
SWING FRAME………………………………………..585
Removal And Installation…………………………585
X-CHANGE™………………………………………….587
Removal And Installation…………………………587
BUCKET…………………………………………….589
Backhoe Bucket Teeth Removal And Installation………589
Loader Bucket Teeth Removal And Installation……….589
BUCKET POSITIONING LINK……………………………..591
Removal And Installation…………………………591
CENTER FLOOR PANEL………………………………….593
Removal And Installation…………………………593
STABILIZER…………………………………………597
Removal And Installation…………………………597
ELECTRICAL SYSTEM AND ANALYSIS…………………………..599
ELECTRICAL SCHEMATIC………………………………..601
ELECTRICAL SYSTEM INFORMATION………………………..603
Troubleshooting Chart……………………………603
Description…………………………………….604
Fuse Location…………………………………..604
Relay Location………………………………….604
BATTERY……………………………………………605
Removal And Installation…………………………605
Servicing The Electrical System…………………..606
Using A Booster Battery (Jump Starting)……………607
ALTERNATOR…………………………………………609
Adjusting The Alternator Belt…………………….609
Description…………………………………….609
Tests………………………………………….610
Alternator Output Test…………………………..610
Full Field Test…………………………………611
Alternator Regulator Test………………………..611
Alternator Regulator Test With Voltmeter…………..612
Removal And Installation…………………………613
Parts Identification…………………………….614
Pulley Removal And Installation…………………..615
Disassembly And Assembly…………………………616
Rotor Continuity Test……………………………619
Stator Continuity Test…………………………..619
Rectifier Continuity (Diode) Test…………………620
Brush Length……………………………………620
STARTER……………………………………………621
Removal And Installation…………………………621
Checking The Starter In The Loader………………..621
Parts Identification…………………………….623
Disassembly…………………………………….624
Inspection And Repair……………………………629
No Load Test……………………………………633
Assembly……………………………………….634
FRONT LIGHTS……………………………………….641
Bulb Removal And Installation…………………….641
Housing Removal And Installation………………….643
TURN INDICATOR LIGHTS (FRONT)………………………..645
Bulb Removal And Installation…………………….645
TURN INDICATOR LIGHTS (REAR)…………………………647
Bulb Removal And Installation…………………….647
CAB LIGHTS…………………………………………649
Bulb Removal And Installation…………………….649
Housing Removal And Installation………………….651
FUEL LEVEL SENDER…………………………………..653
Removal And Installation…………………………653
INSTRUMENT PANEL……………………………………655
Removal And Installation…………………………655
ENGINE SERVICE…………………………………………657
TROUBLESHOOTING…………………………………….659
Chart………………………………………….659
ENGINE SPEED CONTROL………………………………..661
Removal And Installation…………………………661
Cable And Rod Removal And Installation…………….662
TRAVEL PEDAL……………………………………….665
Removal And Installation…………………………665
MUFFLER……………………………………………669
Removal And Installation…………………………669
AIR CLEANER………………………………………..671
Removal And Installation…………………………671
RADIATOR…………………………………………..673
Removal And Installation…………………………673
ENGINE COMPONENTS AND TESTING………………………..675
Valve Clearance Adjustment……………………….675
Engine Compression Checking………………………676
Fuel Shut-Off Solenoid Removal And Installation…….677
Checking Fuel Injection Pump……………………..678
Fuel Injection Pump Removal And Installation……….679
Fuel Injection Pump Timing……………………….681
Fuel Injector Nozzles……………………………682
Fuel Injector Nozzles Removal And Installation……..683
Fuel Injector Nozzles Check………………………684
ENGINE…………………………………………….685
Removal And Installation…………………………685
Mount Replacement……………………………….689
RECONDITIONING THE ENGINE……………………………691
Cylinder Head Removal And Installation…………….691
Cylinder Head Disassembly And Assembly…………….692
Cylinder Head Servicing………………………….693
Cylinder Head Top Clearance………………………693
Valve Guide Checking…………………………….694
Reconditioning The Valve And Valve Seat……………695
Valve Spring……………………………………696
Rocker Arm And Shaft Checking…………………….696
Timing Gearcase Cover Removal And Installation……..697
Idler Gear And Camshaft Removal And Installation……699
Camshaft Servicing………………………………700
Idler Gear And Shaft Servicing……………………701
Timing Gears Checking Backlash……………………702
Fuel Camshaft Removal And Installation…………….703
Fuel Camshaft Governor…………………………..703
Crankshaft Gear Removal And Installation…………..704
Oil Pump Removal And Installation…………………704
Oil Pump Service………………………………..704
Checking Engine Oil Pressure……………………..705
Oil Pump Relief Valve……………………………706
Piston And Connecting Rod Removal And Installation….706
Piston And Connecting Rod Servicing……………….708
Connecting Rod Alignment…………………………710
Crankshaft And Bearings Removal And Installation……710
Crankshaft And Bearings, Servicing………………..712
Cylinder Bore, Checking………………………….715
Water Pump Removal And Installation……………….716
Water Pump Disassembly And Assembly……………….716
FLYWHEEL HOUSING……………………………………717
Removal And Installation…………………………717
FLYWHEEL…………………………………………..719
Removal And Installation…………………………719
Ring Gear Removal And Installation………………..719
DRIVE COUPLER………………………………………721
Removal And Installation…………………………721
TURBO……………………………………………..723
Not Available At Time Of Print……………………723
SPECIFICATIONS…………………………………………725
LOADER SPECIFICATIONS……………………………….727
Loader Backhoe Dimensions………………………..727
Performance…………………………………….728
Controls……………………………………….728
Engine…………………………………………728
Hydraulic System………………………………..729
Electrical……………………………………..729
Drive System……………………………………729
Capacities……………………………………..729
Tires………………………………………….729
ENGINE SPECIFICATIONS……………………………….731
Fuel Injection Nozzles…………………………..731
Fuel Injection Pump……………………………..731
Cylinder Head…………………………………..731
Valves…………………………………………731
Valve Springs…………………………………..732
Valve Timing……………………………………732
Rocker Arms…………………………………….732
Camshaft……………………………………….732
Cylinders………………………………………732
Tappet…………………………………………732
Piston Rings……………………………………733
Pistons………………………………………..733
Crankshaft……………………………………..733
Oil Pump……………………………………….733
Thermostat……………………………………..734
Connecting Rods…………………………………734
Timing Gear…………………………………….734
Engine Bolt Torque………………………………735
Grinding Specifications for the Crankshaft…………736
LOADER BACKHOE TORQUE……………………………….737
Specifications………………………………….737
TORQUE SPECIFICATIONS FOR BOLTS………………………739
Torque For General Metric Bolts…………………..739
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS…………….741
Specifications………………………………….741
CONVERSIONS………………………………………..743
Decimal And Millimeter Equivalents………………..743
U.S. To Metric Conversion………………………..743
SMR…………………………………………………..745
B300-1…………………………………………….745
B300-2…………………………………………….747
B300-3…………………………………………….749
B300-4…………………………………………….751
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DESCRIPTION:
BOBCAT B300 B-Series SN 572311001 Service Manual PDF DOWNLOAD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
- Check that ROPS mounting hardware is tightened and is Bobcat approved.
- The seat belt must be correctly installed, functional and in good condition.
- Check lift arm support device, replace if damaged.
- Machine signs must be legible and in the correct location.
- Foot pedal must return to neutral.
- Check for correct function of the work lights.
- The parking brake must function correctly.
- Enclosure door latches must open and close freely.
- Bob-Tach wedges and linkages must function correctly and be in good condition.
- Safety treads must be in good condition.
- Check for correct function of indicator lamps (Optional on some models).
- Check hydraulic fluid level, engine oil level, and fuel supply.
- Inspect for fuel, oil, or hydraulic fluid leaks.
- Lubricate the loader backhoe.
- Check the condition of the battery and cables.
- Inspect the air cleaner for damage or leaks. Check the condition of the element.
- Check the electrical charging system.
- Check tires for wear and pressure.
- Inspect for loosen or broken parts or connections.
- Operate the loader and check all functions.
- Check for any field modification not completed.
- Recommend to the owner that all necessary corrections be made before the machine is returned to service.
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
G.P