Bobcat T190 Compact Track Loader Service Manual – 6987043 (8-09)

(S/N: 531660001 & Above – S/N: 531760001 & Above)
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This workshop repair service manual PDF download for the T190 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 T190
S/N: 531660001 & Above
S/N: 531760001 & Above

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT LOADER IDENTIFICATION
SAFETY & MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM
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 : 6987043 (8-09)
Total Pages : 888

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 !!!!

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Hydraulic System
Fueling
Starting
Spark Arrestor Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATION
Loader Serial Number
Engine Serial Number
DELIVERY REPORT
LOADER IDENTIFICATION

SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE LOADER
Procedure
LIFT ARM SUPPORT DEVICE
Installing
Removing
OPERATOR CAB
Description
Raising
Lowering
Cab Door Sensor
Special Applications Kit
Special Applications Kit Inspection And Maintenance
TRANSPORTING THE LOADER ON A TRAILER
Loading And Unloading
Fastening
TOWING THE LOADER
Procedure
REMOTE START TOOL KIT-MEL1563
Remote Start Tool – MEL1563
Service Tool Harness Control – MEL1565
Service Tool Harness Communicator – MEL1566
Remote Start Procedure
REMOTE START TOOL (SERVICE TOOL) KIT – 6689779
Description
Remote Start Tool (Service Tool) – 6689778
Loader Service Tool Harness – 6689747
Computer Service Tool Harness – 6689746
Remote Start Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Elements
ENGINE COOLING SYSTEM
Cleaning
Checking Level
Removing And Replacing Coolant
FUEL SYSTEM
Fuel Specifications
Biodiesel Blend Fuel
Filling The Fuel Tank
Fuel Filter
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil Chart
Removing And Replacing Oil And Filter
HYDRAULIC / HYDROSTATIC SYSTEM
Checking And Adding Fluid
Hydraulic / Hydrostatic Fluid Chart
Removing And Replacing Hydraulic Fluid
Removing And Replacing Hydraulic / Hydrostatic Filter
Removing And Replacing Case Drain Filters
Removing And Replacing Hydraulic Charge Filter
Breather Cap
BOB-TACH (HAND LEVER)
Inspection And Maintenance
BOB-TACH (POWER)
Inspection And Maintenance
LUBRICATING THE LOADER
Lubrication Locations
SPARK ARRESTOR MUFFLER
Cleaning Procedure
PIVOT PINS
Inspection And Maintenance
LOADER STORAGE AND RETURN TO SERVICE
Storage
Return To Service
STOPPING THE ENGINE AND LEAVING THE LOADER
Procedure
Emergency Exit

HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting
CYLINDER (LIFT)
Testing
Removal And Installation
Parts Identification
Disassembly And Assembly
CYLINDER (TILT)
Testing
Removal And Installation
Rod End Pivot Pin Bushing And Seal Removal And Installation
Base End Pivot Pin Removal And Installation
Parts Identification
Disassembly And Assembly
CYLINDER (BOB-TACH)
Testing
Removal And Installation
Parts Identification
Disassembly And Assembly
MAIN RELIEF VALVE
Description
Testing
Adjusting
Removal And Installation
HYDRAULIC CONTROL VALVE (STANDARD)
Description
Removal And Installation
Identification Chart
Mount Bracket Removal And Installation
Lift Load Check Valve Removal And Installation
Load Check Valve Removal And Installation (Tilt & Auxiliary)
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)
Port Relief Valve Removal And Installation
Plug Removal And Installation
Rubber Boot Removal And Installation
End Cap / Spool Lock Block Removal And Installation
Lift Spool And Detent Removal And Installation
Tilt Spool Removal And Installation
Auxiliary Spool Removal And Installation
Auxiliary Solenoid Removal And Installation
Solenoid Removal And Installation
Lock Valve Removal And Installation
Lift Arm Bypass Orifice Removal And Installation
Main Relief Valve Removal And Installation
Check Valve Removal And Installation
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
Description
Removal And Installation
Actuator Removal And Installation (Out of Loader)
Identification Chart
Mount Bracket Removal And Installation
Lift Load Check Valve Removal And Installation
Load Check Valve Removal And Installation (Tilt & Auxiliary)
Anti-Cavitation Valve Removal And Installation (Lift, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End)
Port Relief Valve Removal And Installation
Plug Removal And Installation
End Cap Block Removal And Installation
Lift Spool And Detent Removal And Installation
Tilt Spool Removal And Installation
Auxiliary Spool Removal And Installation
Auxiliary Solenoid Removal And Installation
Solenoid Removal And Installation
Lock Valve Removal And Installation
Lift Arm Bypass Orifice Removal And Installation
Main Relief Valve Removal And Installation
Check Valve Removal And Installation
LIFT ARM BYPASS CONTROL VALVE
Description
Testing
Removal And Installation
Disassembly And Assembly
HYDRAULIC PUMP (STANDARD)
Description
Pump Test At Quick Couplers
Direct Pump Test (Standard Section)
Direct Pump Test (Charge Section)
Removal And Installation
Hydraulic Pump Startup
Parts Identification
Disassembly And Assembly
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)
Description
Pump Test At Quick Couplers
Direct Pump Test (Standard Section)
Direct Pump Test (Charge Section)
Direct Pump Test (High Flow Section)
Removal And Installation
Hydraulic Pump Startup
Parts Identification
Disassembly And Assembly
HYDRAULIC PUMP (SJC)
Description
Pump Test At Quick Couplers
Direct Pump Test (Standard Section)
Direct Pump Test (Charge Section)
Removal And Installation
Hydraulic Pump Startup
Parts Identification
Disassembly And Assembly
HYDRAULIC PUMP (SJC) (HIGH FLOW)
Description
Pump Test At Quick Couplers
Direct Pump Test (Standard Section)
Direct Pump Test (Charge Section)
Direct Pump Test (High Flow Section)
Removal And Installation
Hydraulic Pump Startup
Parts Identification
Disassembly And Assembly
HYDRAULIC/HYDROSTATIC FILTERS
Description
Housing Removal And Installation
Charge Filter Housing Removal And Installation
HYDRAULIC FLUID RESERVOIR
Description
Removal And Installation
Hydraulic Fluid Screen
OIL COOLER
Description
Removal And Installation
BUCKET POSITION VALVE
Description
Solenoid Removal And Installation
Solenoid Testing
Removal And Installation
Disassembly And Assembly
REAR AUXILIARY DIVERTER VALVE
Description
Solenoid Testing
Removal And Installation
Disassembly And Assembly
BOB-TACH (POWER) BLOCK
Description
Removal And Installation
Disassembly And Assembly
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
Description
Removal And Installation
Disassembly And Assembly
HIGH FLOW VALVE
Description
High Flow Relief Valve Testing
High Flow Relief Valve Adjustment
Solenoid Testing
Removal And Installation
Disassembly And Assembly

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Description
Troubleshooting
HYDROSTATIC MOTOR
Description
Removing And Replacing Oil
Removal And Installation
Parts Identification
Disassembly And Assembly
CHARGE PRESSURE
Description
Testing
Sender Removal And Installation
Adjusting
HYDROSTATIC PUMP
Description
Replenishing / High Pressure Relief Valve Removal And Installation
Removal And Installation
Hydrostatic Pump Startup
Parts Identification (Left Half)
Parts Identification (Right Half)
Disassembly
Assembly
HYDROSTATIC PUMP (SJC)
Description
Hydraulic Controller Removal And Installation
Removal And Installation
Hydrostatic Pump Startup
Parts Identification
High Pressure Relief And Bypass Valve
Charge Relief Valve
Disassembly And Assembly
Mechanical Neutral Adjustment
Hydraulic Controller Neutral Adjustment
DRIVE BELT
Description
Shield Removal And Installation
Adjusting
Belt Removal And Installation
Tensioner Pulley Removal And Installation
Tensioner Pulley Parts Identification
Tensioner Pulley Disassembly
Tensioner Pulley Assembly
CASE DRAIN FILTER
Description
Disassembly And Assembly

DRIVE SYSTEM
BRAKE
Description
Right Motor Brake Test
Left Motor Brake Test
Block Removal And Installation
Block Disassembly And Assembly
TRACK CARRIAGE COMPONENTS
Description
Checking Tension
Adjusting Tension
Track Removal And Installation
Idler (Front) Removal And Installation
Idler (Rear) Removal And Installation
Roller Removal And Installation
Sprocket Removal And Installation
Carriage Removal And Installation
Track Damage Identification

MAIN FRAME
SEAT BAR
Description
Removal And Installation
Disassembly And Assembly
Compression Spring Disassembly And Assembly
OPERATOR CAB
Gas Cylinder Removal And Installation
Gas Cylinder Bracket Disassembly And Assembly
Removal And Installation
OPERATOR SEAT (SUSPENSION)
Removal And Installation
Slide Rail Removal And Installation
Seat Belt Removal and Installation
Lower Cushion Removal And Installation
Back Cushion Removal And Installation
Shock Removal And Installation
3-Point Seat Belt Removal And Installation
BOB-TACH (HAND LEVER)
Description
Removal And Installation
Lever And Wedge Disassembly And Assembly
Pivot Pin Bushing And Seal Removal And Installation
BOB-TACH (POWER)
Description
Removal And Installation
Lever And Wedge Disassembly And Assembly
Pivot Pin Bushing And Seal Removal And Installation
LIFT ARMS
Stabilizer Bar Removal And Installation
Link Removal And Installation
Removal And Installation
REAR GRILL
Removal And Installation
REAR DOOR
Removal And Installation
Striker Removal and Installation
Striker Disassembly and Assembly
Striker (Adjusting)
Latch Removal And Installation
FUEL TANK
Removal And Installation
Fuel Level Sender Removal And Installation
Fuel Fill Screen Removal And Installation
CONTROL PEDALS AND LINKAGES
Description
Pedal Removal And Installation
Linkage Removal And Installation
Pedal (Adjusting)
CONTROL PEDALS (ACS)
Description
Foot Sensor Removal And Installation
Foot Pedal Removal And Installation
Foot Pedal Linkage Disassembly And Assembly
CONTROL PANEL
Description
Removal And Installation
Shock Removal And Installation
Shaft Removal And Installation
Shaft Disassembly And Assembly
Linkage Removal And Installation
Pintle Arm Disassembly And Assembly
Linkage Neutral (Adjusting)
Linkage Travel (Adjusting)
CONTROL PANEL (SJC)
Description
Removal And Installation
CONTROL HANDLE / LEVER
Description
Lever Removal And Installation
Boot Removal And Installation
CONTROL HANDLE / LEVER (ACS)
Description
Handle Sensor Removal And Installation
Handle Removal And Installation
Handle Disassembly And Assembly
Lever Removal And Installation
Boot Removal And Installation
CONTROL HANDLE / LEVER (SJC)
Description
Joystick Testing
Joystick Removal And Installation
Joystick Mount Removal And Installation
ACCESS PANEL (INSIDE)
Removal And Installation (Left)
Removal And Installation (Right)
ACCESS PANEL (INSIDE) (SJC)
Removal And Installation (Left)
Removal And Installation (Right)
WINDOW (REAR)
Removal
Installation (Split Molding)
Installation (Continuous Molding)
WINDOW (TOP)
Removal And Installation
WINDOW (SIDE)
Removal And Installation
WINDOW (CAB DOOR)
Removal (Standard Window)
Installation (Standard Window)
Removal And Installation (Special Applications Window)
CAB DOOR
Description
Removal And Installation
Aligning
Adjusting
Checking Operation

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Standard Cab Harness Connectors
Deluxe Cab Harness Connectors
Mainframe Harness Connectors
Description
Troubleshooting
Fuse And Relay Location / Identification
Solenoid Testing
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
ALTERNATOR
Belt Adjustment
Belt Replacement
Charging System Inspection
Alternator Voltage Testing
Low Voltage Testing
High Voltage Testing
Removal And Installation
Parts Identification
STARTER
Testing
Removal And Installation
Parts Identification
INSTRUMENT PANELS
Left Panel
Standard Key Panel
Deluxe Instrumentation Panel
Side Panel
Front Panel
Front Panel Removal And Installation
Removal And Installation (Left And Right)
Key Switch Removal And Installation
Alarm Removal And Installation
LIGHTS
Front Removal And Installation
Rear Removal And Installation
Cab Light Removal And Installation
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY)
Description
Connector Identification
Removal and Installation
BOBCAT CONTROLLER (ACS)
Description
Connector And Wire Identification
Removal And Installation
BOBCAT CONTROLLER (SJC) (DRIVE)
Description
Connector Identification
Removal and Installation
SPEED SENSOR (SJC)
Description
Testing
Removal And Installation
DIAGNOSTIC SERVICE CODES
Viewing Service Codes (Standard Key Panel)
Viewing Service Codes (Deluxe Instrumentation Panel)
Service Codes List
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
Description
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 Bypass Control
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC)
Troubleshooting
SEAT BAR SENSOR
Description
Troubleshooting
Testing
Removal And Installation
Bobcat Interlock Control System (BICS) Circuit Test
TRACTION LOCK
Description
Troubleshooting
Inspecting
CONTROL SYSTEM (ACS)
Description
Troubleshooting
Handle Sensor Connector Disassembly And Assembly
Switch Handle Removal
Switch Handle Installation
Actuator Connector Disassembly And Assembly
Handle Lock Solenoid Removal And Installation
Handle Lock Solenoid Disassembly And Assembly
Foot Sensor Disassembly And Assembly
Foot Lock Solenoid Removal And Installation
ELECTRICAL / HYDRAULIC CONTROLS
Identification Chart
ELECTRICAL / HYDRAULIC CONTROLS (SJC)
Identification Chart
SERVICE PC (LAPTOP COMPUTER)
Connecting Remote Start Tool
Connecting Remote Start Tool (Service Tool)
CALIBRATION
Description
Actuator Testing
Lift And Tilt Calibration (ACS)
Lift And Tilt Calibration (SJC)
Hydrostatic Pump Calibration (SJC)
STEERING DRIFT COMPENSATION
Description
Operation
FLYWHEEL RPM SENSOR
Description
Adjusting
CONTROL PANEL SETUP
Right Panel Setup (Deluxe Instrumentation Panel)
Attachment Control Information (Deluxe Instrumentation Panel)
PASSWORD SETUP
Password Description
Changing The Owner Password
Changing The User Passwords
Password Lockout Feature
MAINTENANCE CLOCK
Description
Setup
Reset
BACK-UP ALARM SYSTEM
Description
Inspecting
Adjusting Switch Position
Troubleshooting (Standard And ACS)
Troubleshooting (Joystick)
Alarm Removal And Installation
Switch Removal And Installation

ENGINE SERVICE
ENGINE INFORMATION
Description
Engine Specifications
Engine Torque Values
Troubleshooting
Removal And Installation
Engine Mount Replacement
Compression – Checking
ENGINE SPEED CONTROL
Removal And Installation
ENGINE SPEED CONTROL (SJC)
Removal And Installation
Disassembly And Assembly
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
ENGINE COOLING SYSTEM
Radiator Removal And Installation
Hydraulic Fan Description
Hydraulic Fan Disassembly And Assembly
Blower Housing Removal And Installation
Fan Removal And Installation
Hydraulic Fan Motor Removal And Installation
Water Pump Removal And Installation
Water Pump Disassembly And Assembly
Thermostat Housing Removal And Installation
Thermostat – Checking
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Inspection
Engine Oil Pressure – Testing
FUEL SYSTEM
Fuel Shutoff Solenoid – Checking
Fuel Shutoff Solenoid Removal And Installation
Fuel Injection Pump – Checking
Fuel Injection Pump Removal And Installation
Governor Disassembly And Assembly
Fuel Camshaft Removal And Installation
Fuel Injection Pump – Timing
Fuel Injector Removal And Installation
Fuel Injector Nozzle Pressure – Checking
Nozzle Spraying Condition
Valve Seat Tightness
CYLINDER HEAD
Glow Plugs – Testing
Glow Plugs Removal And Installation
Valve Clearance Adjustment
Valve Timing, Checking
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head – Servicing
Cylinder Head Top Clearance
Valve Guide-Checking
Reconditioning The Valve And Valve Seat
Valve Spring
Valve Tappets
Rocker Arm And Shaft Checking
Push Rod Alignment – Checking
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod – Servicing
Cylinder Bore – Checking
Connecting Rod Alignment
Crankshaft Gear Removal And Installation
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings – Servicing
CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Removal And Installation
Timing Gears Backlash-Checking
Idler Gear And Camshaft Removal And Installation
Camshaft – Servicing
Idler Gear And Shaft Servicing
TURBOCHARGER
Description
Testing
Removal And Installation
FLYWHEEL AND HOUSING
Flywheel Removal And Installation
Ring Gear Removal And Installation
Housing Removal And Installation

HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW
Description
Chart
Components
Safety Equipment
REGULAR MAINTENANCE
Filters
Compressor Drive Belt Adjustment
Compressor Drive Belt Replacement
Condenser
Air Conditioning Lubrication
Air Conditioning Service Chart
Evaporator / Heater Coil
TROUBLESHOOTING
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
The Compressor Does Not Operate At All, Or Operates Improperly
Gauge Pressure Related Troubleshooting
Troubleshooting Tree
Temperature / Pressure Chart
Poor A/C Performance
HVAC Repair And Leaks
Electrical System
Engine Coolant Bypassing The Heater Valve
Heater Valve Not Opening Or Closing
SYSTEM CHARGING AND RECLAMATION
Refrigerant Identification
Reclamation And Charging With Recovery / Charging Unit
Charging With A Manifold Gauge Set
COMPRESSOR
Removal And Installation
Oil
Oil Check
Clutch Disassembly And Assembly
CONDENSER
Removal And Installation
RECEIVER / DRIER
Receiver / Drier Removal And Installation
Pressure Relief Valve Removal And Installation
Pressure Switch Removal And Installation
Schraeder Valve Removal And Installation
EVAPORATOR / HEATER UNIT
Removal And Installation
THERMOSTAT
Removal And Installation
EXPANSION VALVE
Removal And Installation
EVAPORATOR COIL
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
Connector Identification
HEATER VALVE
Removal And Installation
Disassembly And Assembly

SPECIFICATIONS
T190 LOADER SPECIFICATIONS
Dimensions
Performance
Controls
Engine
Hydraulic System
Electrical
Drive System
Capacities
Tracks
Ground Pressure
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
Port Seal Fitting
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion Chart

SERVICE MANUAL REVISION
Revision No: T190 – 1
Revision No: T190 – 2
Revision No: T190 – 3
Revision No: T190 – 4

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